Digital Twin Design for Industrial Control Loops on Xilinx Kria SoM with Simulink Integration and Multi-Protocol Network Support

Project in Nutshell: For an oil and gas company in the UAE, Promwad built an industrial digital twin that simulates process objects, such as a distillation column, and lets engineers design and test control loops in real time. Running on a Xilinx Kria SoM, the device links to Simulink in real time, connects to sensors and actuators across EtherCAT, PROFINET, and EtherNet/IP, and can generate and simulate both analog (4-20 mA, 0-10 V) and discrete signals. It logs sensor data to an SD card, giving the client a single tool to optimize processes, evaluate performance, and make informed operational decisions.

Client & Challenge  

An oil and gas company from the United Arab Emirates approached us to design digital twins to create control loops with real-time simulation.

Solution

1. Concept Development 

The device's primary function is to create a digital twin system for technological objects. For example, it involves the simulation of a distillation column and the ability to establish control loops for it. 

2. Hardware Design 

To develop industrial digital twins, we utilised the Xilinx Kria SoM. Our engineering team also prepared a specialised environment that allows real-time communication with Simulink. The device supports all industrial networks, including EtherCAT, PROFINET, EtherNet/IP, etc. 

The client can take data from sensors and write them to an SD card, which is used for the device. 

The completed device has the following characteristics:

• ability to connect sensors and actuators; 
• support of analogue signals 0-20 mA, 4-20 mA, 0-10V and discrete signals 0-5V, 0-24V; 
• simulation of all analogue and discrete signals; 
• display port with visualisation of user interfaces 

Technologies: Matlab, Simulink, C++, Rust, PROFINET, EtherCAT, EtherNet/IP, Qt. 

Business Value 

Our client gains operational efficiency and enhances control and monitoring capabilities by implementing digital twins technology designed with real-time modelling. The ability to collect sensor data and write it to an SD drive provides the convenience of data storage and opens up opportunities for in-depth analysis. Our client uses this data to evaluate performance and analyse trends.