The Evolving Relationship between Simulation and Emulation: Faster than Real-time Controls Testing

Modern facilities, such as automated material handling systems, baggage handling, or manufacturing process systems, are complex systems controlled by various control units on different automation levels. The design and development of these facilities require the application of CAD, simulation, development and testing tools. Traditionally different tools have been used at each stage, and that separation has tended to impede the smooth delivery of the project. In this paper, we show that the same modeling software can be deployed at all stages of the design – from layout and simulation through to controls testing. Additionally we show that by incorporating a PLC emulator, tightly integrated with the virtual clock, and using internal communication channels, that real control logic can also be used at every stage. The engineer has complete control over the level of accuracy for modeling, simulating and emulating, while still running the model faster or slower than real-time.