Soft Real-Time PIL Hub for Deterministic I/O Emulation
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Solution Overview
Problem
Traditional processor-in-the-loop (PIL) simulations for testing control systems are costly, labor-intensive, and often lack the realism of real-time input/output (I/O) networks, leading to difficulties in accurately simulating complex control systems and masking potential faults or errors.
Innovation Solution
A modular software-based real-time hub (RTHub) provides deterministic data transport and I/O emulation, allowing for flexible simulation module swapping and transparent interfacing with control systems, running on a standard operating system to enable accurate and cost-effective testing without requiring custom hardware or software modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional PIL simulations use real I/O networks, then measurement precision and reliability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent creates a software-based virtual I/O network that replicates the behavior and timing characteristics of physical I/O networks. This virtual copy provides the necessary realism for accurate control system testing while avoiding the complexity and cost of actual hardware I/O connections.
Solution Approach 2:
The patent replaces physical mechanical I/O hardware with a software-based virtual I/O network. This substitution maintains the functional characteristics needed for testing while eliminating the complexity of physical wiring and hardware interfaces.
2Measurement precision
If custom PIL simulation solutions are developed for each PLC, then measurement precision is improved, but ease of manufacture and productivity worsen
Solution Approach 1:
The patent creates a universal virtual I/O network platform that can serve multiple different PLCs and control systems. This single platform provides consistent, accurate testing capabilities across various systems without requiring custom development for each specific PLC model.
Solution Approach 2:
The virtual I/O network is designed to be dynamically configurable, allowing it to adapt to different PLC types and communication protocols through software configuration rather than hardware reconfiguration. This enables rapid setup changes for different testing scenarios.
3Ease of operation
If I/O network timing is emulated through memory manipulation, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The patent introduces a virtual I/O network as an intermediary layer between the PLC and the test environment. This intermediary maintains proper timing relationships and communication protocols, providing both ease of operation and timing accuracy that direct memory manipulation cannot achieve.
Data Source
AI summary
A software-based (“soft”) real-time hub designed and implemented for use in simulation (or control testing) systems such as to provide a modular soft-real-time PIL. A simulation system of the present description typically may include one or more of the following useful subsystems or components: (a) a soft-real-time hub; (b) simulation interfaces; and (c) hardware emulation subsystems/devices. The soft-real-time hub is typically a combination of hardware and software adapted to provide deterministic data transport between simulations and input/output (I/O) emulation. By creating a common point, the hub enables simulation modules to be swapped out as the simulation system progresses without the operator having to worry about interface timing, forcing, or data visualization. A desirable aspect of the simulation system is it allows for testing certain conditions by forcing I/O and then seeing how the controller or system under testing responds.