Line in the simulator in parallel — and where it diverged from the model
The same twin that checked the program before start-up executes the running line in parallel in the simulator. The controller and data stay on your site; the cloud and browser are a window for observation.
A twin that is not thrown away after start-up
Before start-up the twin checks the program: the real unit logic runs against the simulator. On the running line the same simulator runs in parallel with it: the same commands go both to the real equipment and to its model in a virtual world with the laws of physics.
Feedback comes from both sides: from drives and sensors, and from the model. The system compares them: where the model expected a signal and the sensor is silent (or the other way round), a finding appears on screen at once — it is not quietly adjusted.
Control of the line stays with the controller and your staff: the shadow receives the same commands and compares responses; it does not replace the controller.
Three steps from start-up to a finding
- The same commands — to line and modelThe program sends the same commands to the real equipment and to its model in the simulator.
- Feedback from both sidesFrom drives and sensors — and from the model in the simulator.
- A deviation is a visible finding“Model expected — sensor silent” (or the other way round) is flagged on screen at once, not quietly adjusted.
The line on screen — by the actuals
Comparison, not guesswork
Model response against the line’s feedback.
The finding is visible
Where the model and the sensor diverged — on screen.
Some units are virtual
The cycle starts on a real neighbour's sensor.
A unit is replaceable
A virtual unit is replaced by a real one without rebuilding the line.
Shadow mode, virtual units and unit replacement are a subject of the implementation.
Model and facts on one screen
| What | Source | What it gives |
|---|---|---|
| Axis facts | Drive feedback over the bus | The line on screen moves as it moves in the shop, not as it was told to |
| Model response | The same command executed in the simulator | Expectation from physics: what to compare the fact with |
| Divergence | Comparison “model expected — sensor silent” (or the other way round) | A visible finding on screen, not a quiet adjustment of the model |
| Virtual unit | The cycle starts on the trigger of a neighbour’s real sensor | A unit not yet in the shop works in the line on screen |
| Unit replacement | A real unit takes the place of a virtual one | The line is not rebuilt: only the source of the facts changes |
What is needed from a running line
- Line twinThe same twin that verified the program before start-up, or one built from the line: units, axes, sensor points.
- Input modulesInstalled on the line; they bring sensor signals for comparison with the model.
- Drive feedbackAxis facts arrive over the EtherCAT bus with the CiA 402 profile.
- ScreenThe line, divergences and virtual units — in the browser; data stays inside your perimeter.
The set of signals and units included in the shadow is fixed in the implementation specification.
One copy for the whole life of the line
Virtual commissioning
Program against the simulator; sensors — from the model through the same input as real ones. The goal is to find logic errors at the desk.
In detail →Line shadow
The same commands go to the line and its model; feedback from both sides is compared. The aim is to see where the running line has diverged from the design.
The model is not written twice: the simulator is built, the controller configuration is printed and the shadow is run from one twin.
What is ready and what is worked out in the implementation
| Capability | Status |
|---|---|
| Line twin and a project of units, links on the “Graph” | works |
| Drive feedback on screen, run log | works |
| Shadow mode on real servos: the same commands into the simulator, responses compared | subject of the implementation |
| Virtual units started by a neighbour's sensor | subject of the implementation |
| Replacing a virtual unit with a real one without rebuilding the line | subject of the implementation |
Three tasks the shadow solves
Find where the line diverged from the intent
A divergence is visible on screen: where the model expected a signal and the sensor is silent. Analysis starts from a fact, not a guess.
Add a unit without stopping
A new unit first works virtually: its cycle starts on the real sensor of its neighbour. When it arrives, the real unit takes its place without rebuilding the line.
Hand over the line with its twin
The integrator hands over the line together with the model, which keeps working after start-up and shows the line to the customer by the facts.
Who it is for
For enterprises
See the running line and its differences from the model at once.
For integrators
Hand over the line together with a twin that keeps working after start-up.
Discuss an implementation
Tell us which line is already running and which signals it has.
Request access