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

An integrated real and virtual manufacturing automation system including a virtual world domain and a real world domain, said system comprising:

• a first real world machine in the real world domain of the system;
• a first primary real world sensor in the real world domain of the system for sensing a position of the first real world machine;
• a primary real world actuator in the real world domain of the system for actuating the first real world machine;
• a virtual world machine in the virtual world domain of the system;
• a primary virtual world sensor in the virtual world domain of the system for sensing the position of the virtual world machine;
• a primary virtual world actuator in the virtual world part domain of the system for actuating the virtual world machine;
• an interface device for transferring signals between the virtual world domain of the system and the real world domain of the system;
• a programmable logic controller configured to control the actuators;
• and
• an input/output (I/O) device that processes signals sent to the programmable logic controller from the sensors and signals sent from the programmable logic controller to the actuators, said programmable logic controller configured to control the operation of the actuators, so as to provide virtual coupling between sensors and actuators in the virtual world domain of the system and the real world domain of the system for both a real part and a virtual part.

An integrated real and virtual manufacturing automation system including a virtual world domain and a real world domain, said system comprising:

• a first real world machine in the real world domain of the system;
• a first primary real world sensor in the real world domain of the system for sensing a position of the first real world machine;
• a primary real world virtual actuator in the real world domain of the system for actuating the first real world machine;
• a virtual world machine in the virtual world domain of the system;
• a primary virtual world sensor in the virtual world domain of the system for sensing the position of the virtual world machine;
• a primary virtual world actuator in the virtual world domain of the system for actuating the virtual world machine;
• an interface device for transferring signals between the virtual world domain of the system and the real world domain of the system;
• a programmable logic controller configured to control the actuators;
• an input/output (I/O) device that processes signals sent to the programmable logic controller from the sensors and signals sent from the programmable logic controller to the actuators, said programmable logic controller configured to control the operation of the actuators, so as to provide virtual coupling between sensors and actuators in the virtual world domain of the system and the real world domain of the system for both a real part and a virtual part;
• a voltage translation device for converting voltage signals transmitted between the input/output device and the interface device so as to provide a direct electrical connection between the real world domain of the system and the virtual world domain of the system;
• and
• duplicated sensors, duplicated actuators and switching devices that by-pass signals depending on the direction of a part flow between the real world domain of the system and the virtual world domain of the system and whether the system is working on the real part or the virtual part.