Methods of integrating real and virtual world using physical sensor/actuator

An integrated real and virtual manufacturing automation system providing a part flow between a virtual world part of the system and a real world part of the system, said system comprising:

• a real world machine in the real world part of the system;
• a primary real world sensor in the real world part of the system for sensing a position of the real world machine;
• a primary real world actuator in the real world part of the system for actuating the real world machine;
• a virtual world machine in the virtual world part of the system;
• a primary virtual world sensor in the virtual world part of the system for sensing a position of the virtual world machine;
• a primary virtual world actuator in the virtual world part of the system for actuating the virtual world machine;
• an interface device for transferring signals between the virtual world part of the system and the real world part of the system;
• a programmable logic controller for controlling the operation of the system;
• and
• an input/output (I/O) device that processes signals sent to the programmable logic controller and signals sent from the programmable logic controller, wherein the programmable logic controller controls the operation of the system where sensors and actuators coupled between the virtual world part of the system and the real world part of the system are physically coupled.

An integrated real and virtual manufacturing automation system providing a part flow between a virtual world part of the system and a real world part of the system, said system comprising:

• a real world machine in the real world part of the system;
• a primary real world sensor in the real world part of the system for sensing a position of the real world machine;
• a primary real world actuator in the real world part of the system for actuating the real world machine;
• a virtual world machine in the virtual world part of the system;
• a primary virtual world sensor in the virtual world part of the system for sensing a position of the virtual world machine;
• a primary virtual world actuator in the virtual world part of the system for actuating the virtual world machine;
• an interface device for transferring signals between the virtual world part of the system and the real world part of the system;
• a programmable logic controller for controlling the operation of the system;
• an input/output (I/O) device that processes signals sent to the programmable logic controller and signals sent from the programmable logic controller, wherein the programmable logic controller controls the operation of the system where sensors and actuators coupled between the virtual world part of the method and the real world part of the method are physically coupled;
• a first complimentary pair of a physical sensor and an actuator and a second complimentary pair of a physical sensor and an actuator in the real world part of the system, wherein the sensor in the first complimentary pair senses signals from the actuator in the first complimentary pair that is driven by the I/O device to by-pass the primary virtual world sensor through the interface device, and wherein the actuator in the second complimentary pair receives signals that are supposed to be sent to the primary virtual world actuator through the interface device from the I/O device and cause the sensor in the second complimentary pair to generate signals;
• and
• duplicated real world sensors, duplicated real world actuators and switching devices in the real world part of the system that by-pass signals from the virtual world part of the system depending on the direction of the part flow between the real world part of the system and the virtual world part of the system and whether the system is working on a real part or a virtual part.