System and method for emulation of an automation control system

• US 9,846,585 B2
• Filed: 05/14/2013
• Issued: 12/19/2017
• Est. Priority Date: 05/14/2013
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Grgic, Richard, Rischar, Charles, Hall, Kenwood, Maturana, Francisco
• Primary Examiner(s): Saxena, Akash
• Application Number:
  US13/894,124
• Publication Number:
  US 20140343918A1
• Time in Patent Office: 1,680 Days
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: G05B 2219/13174 Pc, computer connected to plc to simulate machine
• CPC Class Codes: G05B 2219/13186 Simulation, also of test inputs
• CPC Class Codes: G05B 2219/23258 GUI graphical user interface, icon, function bloc editor, labview
• CPC Class Codes: G05B 2219/23261 Use control template library
• CPC Class Codes: G05B 2219/25067 Graphic configuration control system
• CPC Class Codes: G06F 9/455 Emulation; Interpretation; Software simulation, e.g. virtualisation or emulation of application or operating system execution engines

Abstract

Present embodiments include an automation control system including one or more processors and memories with an application stored on the one or more memories and implemented by the one or more processors. The application includes an interface configured to communicate with automation devices via a communication subsystem. Further, the application includes an operation environment, a programming environment, and an emulation environment. The programming environment is configured to generate device elements corresponding to the automation devices within the operation environment in which the device elements are configured to functionally interact with the automation devices. The emulation environment is configured to automatically host an emulation model of the automation devices based on the device elements generated within the operation environment.

Claims

1. An automation control system, comprising:

one or more processors and memories;

an application stored on the one or more memories and implemented by the one or more processors, the application including an interface configured to communicate with one or more automation devices via a communication subsystem;

a programming environment of the application configured to generate one or more device elements corresponding to the automation devices based on a request to add the one or more device elements, wherein the one or more device elements are configured to provide information regarding an operation of the one or more automation devices to a user via an operation environment, wherein the one or more device elements are communicatively coupled to the one or more automation devices;

the operation environment of the application, wherein the operation environment is configured to depict the device elements on a graphical user interface, wherein the device elements are configured to enable an operator to implement a change to one or more operations of the automation devices during run-time; and

an emulation environment configured to;

cause the one or more device elements to retrieve a copy of logic from the one or more automation devices via the communication subsystem upon addition of the device elements via the programming environment; and

emulate one or more operations of the one or more automation devices based on the logic via an emulation model.

2. The automation control system of claim 1, wherein the emulation environment is configured to automatically host the emulation model of the automation devices based on the device elements generated within the operation environment and interfaces to one or more other devices.

3. The automation control system of claim 1, wherein the emulation model comprises one or more emulation modules with a first set of characteristics defined by a second set of characteristics of the device elements.

4. The automation control system of claim 3, wherein each of the emulation modules is configured to receive input and provide output in a manner that emulates a physical automation device and wherein each of the emulation modules is configured to receive input from a simulation model.

5. The automation control system of claim 4, wherein the physical automation device being emulated includes an input/output device, an automation controller, or a motor drive.

6. The automation control system of claim 1, wherein the emulation model is configured to emulate communications between the automation devices.

7. The automation control system of claim 1, wherein the programming environment is configured to instantiate one of the device elements within the programming environment upon detection of communicative coupling of a physical automation device to the automation control system.

8. The automation control system of claim 1, wherein the emulation environment is configured to facilitate user modification of the emulation model.

9. The automation control system of claim 1, wherein the emulation environment graphically presents in a manner that differs from that in which the operation environment graphically presents.

10. The automation control system of claim 1, wherein the interface is configured to communicate with the emulation model via the communication subsystem.

11. The automation control system of claim 1, comprising an emulation trigger within the programming environment, wherein actuation of the emulation trigger causes activation of the emulation environment.

12. A method, comprising:

configuring an operation environment by instantiating a device element within a programming environment in response to a first input received from an operator via a graphical user interface, wherein the device element is configured to control one or more operational characteristics of a physical automation device and provide information regarding operation of the physical automation device to a user via the operation environment, wherein the device element is communicatively coupled to the physical automation device;

retrieving, via the instantiated device element, a copy of logic from the physical automation device via a communication subsystem configured to allow communication between the graphical user interface and the physical automation device upon instantiation of the instantiated device element;

emulating, via an emulation environment, the one or more operations of the physical automation system based on the logic;

receiving a second input from the operator via the instantiated device element in the operation environment, wherein the second input is configured to change the instantiated device element to adjust the one or more operational characteristics of the physical automation device; and

upon implementation of the change to the instantiated device element via the operation environment, automatically generating an emulation module of an emulation model within the emulation environment of the instantiated device element with respect to the change, wherein the emulation module is configured to emulate the physical automation device based on the one or more adjusted operational characteristics of the device element.

13. The method of claim 12, comprising activating the emulation environment based on an input received via an emulation trigger depicted in the programming environment.

14. The method of claim 12, comprising utilizing at least one memory and at least one processor to perform instantiations of one or more device elements and one or more modules, and performing simulations.

15. The method of claim 12, comprising providing a directory tree including one or more instantiated device elements that are configured for emulation.

16. The method of claim 12, wherein the first and second inputs are generated by a user-input device.

17. The method of claim 12, comprising managing virtual clock time by expanding time steps, contracting time steps, or rewinding time steps.

18. One or more tangible, non-transitory machine-readable media comprising instructions configured to be carried out on an electronic device configured to coordinate with an automation control system, the instructions configured to:

populate an operation environment by instantiating a device element within a programming environment in response to a first input by an operator via a graphical user interface, wherein the device element is configured to control one or more operational characteristics of a physical automation device of the automation control system and provide information regarding the one or more operational characteristics of the physical automation device;

populate an emulation model within an emulation environment with an emulation module of the instantiated device element, wherein the emulation environment is configured to cause the one or more device elements to retrieve a copy of logic from the one or more automation devices via the communication subsystem upon instantiation of the instantiated device element and emulate the one or more operational characteristics of the physical automation device based on the logic; and

upon receiving a second input from the operator, wherein the second input is configured to implement a change to the instantiated device element via the operation environment, automatically populate an emulation model within the emulation environment with an emulation module of the instantiated device element with respect to the change, wherein the emulation module is configured to emulate the physical automation device based on the operational characteristics of the device element and the change.

19. The one or more tangible, non-transitory machine-readable media of claim 18, comprising instructions configured to automatically populate the emulation model with the emulation module when the emulation environment is activated.

20. The one or more tangible, non-transitory machine-readable media of claim 18, comprising instructions configured to provide output to or receive input from a simulation component.

21. The one or more tangible, non-transitory machine-readable media of claim 18, configured to provide remote access to the programming environment.