Object controller digital twin system

Patent metadata

Field	Value
Publication number	US-2025272454-A1
Application number	US-202519208657-A
Country	US
Kind code	A1
Filing date	May 15, 2025
Priority date	Aug 25, 2023
Publication date	Aug 28, 2025
Grant date	—

Abstract

An object controller digital twin system includes a system running layer, an environment construction layer, a test layer and an analysis layer. The system running layer is used for simulating a running state of the digital twin object controller; the environment construction layer is used for implementing the construction of a system running environment; the test layer is used for transferring a test instruction to the system running layer so as to perform a simulation test in the system running layer; and the analysis layer receives test returned data transferred by the test layer, and performs fault cause analysis and recording on fault-related data in the test returned data. By simulating the running state of the object controller on a host computer, the object controller digital twin system enables embedded development work to no longer rely on customized hardware.

First claim

What is claimed is:

1 . An object controller digital twin system, comprising:
a system running layer, wherein the system running layer loads a central processing unit (CPU) module for simulating a running state of a digital twin object controller; an environment construction layer, wherein binary codes are loaded in the environment construction layer to implement a construction of a system running environment in the system running layer; a test layer, configured for transferring a test instruction to the system running layer to perform a simulation test in the system running layer, wherein the test layer uploads test returned data generated after the simulation test is completed; and an analysis layer, configured for receiving the test returned data transferred by the test layer, and performing fault cause analysis and recording on fault-related data in the test returned data.

2 . The object controller digital twin system according to claim 1 , wherein the system running layer uses a software to simulate an embedded kernel on a host computer to simulate a register, a memory and an instruction set.

3 . The object controller digital twin system according to claim 2 , wherein the embedded kernel is an MCF54418 embedded kernel, and the instruction set is a Cold Fire V4 instruction set.

4 . The object controller digital twin system according to claim 2 , wherein the system running layer executes an embedded software on the host computer, and the embedded software comprises a ReWorks CERT operating system and an application software.

5 . The object controller digital twin system according to claim 1 , wherein the system running layer comprises a safety communication module and a GUEST module, and running states of the safety communication module and the GUEST module are simulated in the system running layer.

6 . The object controller digital twin system according to claim 5 , wherein the system running layer is configured for simulating a processing unit comprising a virtual control unit (VCU) as a core and a peripheral function circuit configured for simulating an external signal as an input of the VCU.

7 . The object controller digital twin system according to claim 6 , wherein the VCU has a dual-channel architecture, each channel of the dual-channel architecture is provided with a CPU, and a high-frequency 2oo2 interactive communication is implemented between dual channels by simulating an internal serial port.

8 . The object controller digital twin system according to claim 7 , wherein an external network communication interface, a serial port communication interface and a controller area network (CAN) communication interface are provided between the system running layer and an external interlocking system, and the CAN communication interface of the system running layer is configured for connection and communication with a CAN bus of a real object controller system.

9 . The object controller digital twin system according to claim 8 , wherein the safety communication module comprises a plurality of external network ports and an internal network port, wherein the plurality of external network ports are configured for external network communication, and the internal network port is configured for communicating with a safety communication module of another module.

10 . The object controller digital twin system according to claim 5 , wherein the safety communication module and the GUEST module run independently of each other.

11 . The object controller digital twin system according to claim 5 , wherein the environment construction layer reads a pre-defined application design input file, constructs hardware device resources according to the pre-defined application design input file to form a multi-configuration item multi-machine test environment, virtually runs a multi-chip CPU and peripherals in a host computer, and deploys a binary application program file and a binary application data file to the safety communication module and the GUEST module.

12 . The object controller digital twin system according to claim 1 , wherein the system running layer, the environment construction layer, the test layer and the analysis layer are physically isolated from one another, and the system running layer, the environment construction layer, the test layer and the analysis layer are configured to run independently, and are further configured to implement real-time interconnection by interfaces.

Assignees

• Casco Signal Ltd

Inventors

• Xu Jing
• Yang Shuo
• Ji Zhijun
• Wang Hexiang
• Wang Guoxing
• Ye Ruiyuan
• Zheng Xiaojie
• Xu Xipeng

Classifications

• G06F11/079

  Root cause analysis, i.e. error or fault diagnosis (in a hardware test environment G06F11/22; in a software test environment G06F11/36) · CPC title

• G05B17/02

  electric · CPC title

• G06F8/20

  Software design · CPC title

• Y02P90/02

  Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] · CPC title

• G06F9/45504 Primary

  Abstract machines for programme code execution, e.g. Java virtual machine [JVM], interpreters, emulators · CPC title