US 12,591,218 B2Granted

Industrial digital twin model environment

AssigneeRockwell Automation Technologies, Inc.

InventorsLeo T Kilfoy, Michael J Tresh, Bruce T. McCleave, Jr., Daniel C. Rischar, Stephen C. Briant, Ryan P. Dunn

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Abstract

A cloud-based digital twin modeling and testing system is capable of hosting multiple applications that can be used to simulate and test versions of a control design prior to deployment, including but not limited to control programming applications, controller emulation applications, machine simulation applications, or other such platforms. The digital twin modeling environment renders an interface display that allows a user to easily build a testable digital model of a control system by connecting components of a proposed control project to these applications. The system also allows the user to define inputs and test scenarios to be executed as a simulation. Based on the connections, inputs, and test scenarios defined by the user, the modeling system leverages the hosted applications as needed to execute the defined test scenarios and generate predicted metrics for the proposed control system design.

Claims20

Dependent claims

A system, comprising:

a memory that stores executable components;
and
a processor, operatively coupled to the memory, that executes the executable components, the executable components comprising:
a user interface component configured to
render, a design canvas on a client device,
render, on the design canvas, first icons representing development and testing applications that are hosted on the system or linked to by the system, wherein the development and testing applications comprise at least an industrial control programming application and a controller emulation application,
receive, via interaction with the design canvas, selections of industrial control project files to be included in a system model, wherein the industrial control project files comprise at least an industrial control program, a human-machine interface (HMI) application, and a virtual model of an industrial machine,
render, on the design canvas, second icons representing the industrial control project files, and
receive, via interaction with the design canvas, a link between a selected one of the second icons representing an industrial control project file, of the industrial control project files, and a selected one of the first icons representing an application, of the development and testing applications, that is to execute the one of the industrial control project files;
a modeling component configured to generate the system model representing an industrial control system based on the industrial control project files and the link between the selected one of the second icons and the selected one of the first icons;
and
a testing component configured to perform a test execution on the system model that simulates operation of the industrial control system and generates performance metric data for the system model based on the test execution,
wherein
the link instructs the testing component to execute, as part of the test execution, the industrial control project file using an instance of the application.

11 more elements

A method, comprising:

rendering, on a client device by a system comprising a processor, a design canvas;
rendering, by the system on the design canvas, first icons representing development and testing applications that are hosted on the system or linked to by the system, wherein the development and testing applications comprise at least an industrial control programming application and a controller emulation application;
receiving, by the system via interaction with the design canvas, selections of industrial control project files to be included in a system model representing an industrial automation system, wherein the industrial control project files comprise at least an industrial control program and a human-machine interface (HMI) application, and a virtual model of an industrial machine;
rendering, by the system on the design canvas, second icons representing the industrial control project files;
receiving, by the system via interaction with the design canvas, a link between a selected one of the second icons representing an industrial control project file, of the industrial control project files, and a selected one of the first icons representing an application, of the development and testing applications, that is to execute the one of the industrial control project files;
generating, by the system, the system model based on the industrial control project files and the link between the selected one of the second icons and the selected one of the first icons;
performing, by the system, a test execution on the system model that simulates operation of the industrial automation system, wherein the performing comprises executing, as part of the test execution, the industrial control project file using an instance of the application in accordance with the link;
and
generating, by the system, performance metric data for the system model based on the test execution.

6 more elements

A non-transitory computer-readable medium having stored thereon instructions that, in response to execution, cause a system comprising a processor to perform operations, the operations comprising:

rendering, on a client device, a design canvas;
rendering, on the design canvas, first icons representing development and testing applications that are hosted on the system or linked to by the system, wherein the development and testing applications comprise at least an industrial control programming application and a controller emulation application;
receiving, via interaction with the design canvas, selections of industrial control project files to be included in a system model representing an industrial control system, wherein the industrial control project files comprise at least an industrial control program and a human-machine interface (HMI) application, and a virtual model of an industrial machine;
rendering, on the design canvas, second icons representing the industrial control project files;
receiving, via interaction with the design canvas, a link between a selected one of the second icons representing an industrial control project file, of the industrial control project files, and a selected one of the first icons representing an application, of the development and testing applications, to be used to execute the one of the industrial control project files;
generating the system model based on the industrial control project files and the link between the selected one of the second icons and the selected one of the first icons;
performing a test execution on the system model that simulates operation of the industrial automation system, wherein the performing comprises executing, as part of the test execution, the industrial control project file using an instance of the application based on the link;
and
generating performance metric data for the system model based on the test execution.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/350,058Filed 11 Jul 2023
Published: US 2025/0021078 A116 Jan 2025
Granted: 31 Mar 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification7 codes

G05B 19/4155
Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to…
G06F 30/20
Computer-aided design [CAD]: design optimisation, verification or simulation
G05B 19/41885
Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible…:…
G05B 2219/31449
From computer integrated manufacturing till monitoring: monitor workflow, to optimize business, industrial processes