Wiring Diagram Emulation for Virtual Control Connectivity Testing
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Solution Overview
Problem
Conventional industrial automation system design requires separate tools for mechanical and control engineering, leading to difficulties in maintaining synchronization between mechanical and control designs, and the need for separate simulation models for testing control programming, which complicates the workflow and increases development time.
Innovation Solution
An integrated CAD system that allows users to label mechanical CAD models with aspect metadata, transforming them into simulation-capable digital twins that can be exported for virtual commissioning and testing, enabling simultaneous simulation of mechanical and control designs within a unified platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate tools are used for mechanical and control engineering, then each domain can be designed independently, but synchronization between mechanical and control designs becomes difficult and development time increases
Solution Approach 1:
The patent merges mechanical and control engineering tools into a single integrated CAD system. The system allows users to create and annotate mechanical CAD models with control-related metadata, enabling both mechanical and control designs to be developed, visualized, and synchronized within one unified platform rather than requiring separate tools and manual synchronization processes.
2Ease of manufacture
If separate simulation models are used for testing control programming, then control logic can be tested independently, but the workflow becomes complicated and synchronization is lost
Solution Approach 1:
The patent combines mechanical modeling and control simulation capabilities into a single integrated system. The CAD system generates annotated models that include both mechanical geometry and control metadata, allowing control programming to be tested directly within the same environment where mechanical designs are created, eliminating the need for separate simulation models and complex data transfer workflows.
Solution Approach 2:
The integrated CAD system performs multiple functions including mechanical design, control annotation, and simulation testing within a single platform. The system can create mechanical models, add control-related metadata, generate wiring diagrams, and simulate control logic all through one unified toolset, replacing the need for multiple specialized tools.
3Productivity
If mechanical CAD models are transformed into simulation-capable digital twins with aspect metadata, then simultaneous simulation of mechanical and control designs is enabled, but the complexity of model transformation increases
Solution Approach 1:
The system enables automatic generation of simulation-capable digital twins from mechanical CAD models through automated annotation processes. The CAD system automatically adds control-related metadata, aspect information, and simulation parameters to mechanical models, reducing the manual effort and complexity required to transform basic CAD models into fully functional simulation-ready digital twins.
Data Source
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AI summary
An industrial control design and testing system supports emulation of a 2D representation of control system wiring between an industrial controller and Held hardware. The design and testing system can simulate wiring diagrams to virtually confirm connectivity between the controller and the I/O devices in the field. This approach can also confirm wiring connections that do not pass through the controller, including emergency stop pushbuttons or other electrical connections that do not feed back into the controller.