Virtual PLC Network Simulation for Cost-Effective Verification
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Solution Overview
Problem
Conventional simulation methods for large-scale PLC networks require complex and costly verification environments, as they necessitate a personal computer for each PLC connected to the network.
Innovation Solution
A simulation device that constructs a virtual network system with multiple virtual PLC systems, allowing for synchronized operation and simulation of a network system, thereby simplifying the configuration and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one personal computer (PC) operates one virtual PLC for each PLC connected to a network, then the operation of PLC programs can be simulated and verified, but the verification environment becomes complicated and costly for large-scale PLC networks
Solution Approach 1:
Multiple virtual PLCs are merged into a single integrated simulation environment on one PC. The patent implements a host PC that can simultaneously simulate and coordinate multiple virtual PLCs (Virtual PLC-A, Virtual PLC-B, etc.) within a unified network simulation framework, eliminating the need for separate physical PCs for each PLC while maintaining verification accuracy.
Solution Approach 2:
The host PC is designed to perform multiple functions simultaneously: it acts as the simulation host, network controller, and coordinator for multiple virtual PLCs. The single PC universal platform can simulate different PLC models, manage network communication protocols, and verify PLC programs across the entire network system, replacing the need for dedicated PCs for each function.
2Reliability
If multiple PCs are used to simulate multiple virtual PLCs in a network, then accurate operation verification is achieved, but the cost of constructing the verification environment increases significantly
Solution Approach 1:
The patent consolidates hardware resources by merging multiple PC systems into a single host PC that simulates multiple PLCs. The host PC's processing power, memory, and storage are shared across all virtual PLC simulations, reducing hardware costs while maintaining verification accuracy through virtualization technology.
Solution Approach 2:
Instead of using physical PLC hardware or separate PCs for each PLC, the patent creates virtual copies of PLCs that run on a single host PC. These virtual PLCs replicate the functionality and behavior of actual PLCs, enabling accurate verification without the need for expensive physical hardware for each unit.
3Device complexity
If a simplified simulation environment is used to reduce complexity and cost, then hardware requirements are lowered, but the ability to accurately verify PLC network operations may be compromised
Solution Approach 1:
The patent introduces a simulation environment as an intermediary layer between the physical PLCs and the host PC. This virtualization layer accurately replicates network communication protocols, data transmission, and PLC operations, ensuring verification reliability while keeping the physical hardware simple (just one host PC). The simulation environment mediates all interactions, maintaining fidelity without complex physical infrastructure.
Data Source
AI summary
A simulation device includes a storage unit to store a PLC program for operating PLC systems, and a simulation unit to construct a virtual network system simulating a configuration of a network system that includes the PLC systems, and simulate an operation of the network system using the virtual network system and the PLC program. The network system includes the PLC systems, the virtual network system includes a plurality of virtual PLC systems to simulate an operation of the PLC systems, and the simulation unit causes the virtual PLC systems to execute the PLC program while synchronizing time in the virtual network system.