Digital Twins Design for Control Loops in Industrial Networks

Project in Nutshell: we developed digital twins for an oil and gas company using real-time modelling. Based on Xilinx Kria SoM, the solution collects and analyses sensor data in industrial networks, providing the client with a tool for optimising processes and making informed decisions in their operations.

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.