Development of Economic Water Usage Sensor and Cyber-Physical Systems Co-Simulation Platform for Home Energy Saving

In this thesis, two Cyber-Physical Systems (CPS) approaches were considered to reduce residential building energy consumption. First, a flow sensor was developed for residential gas and electric storage water heaters. The sensor utilizes unique temperature changes of tank inlet and outlet pipes upon water draw to provide occupant hot water usage. Post processing of measured pipe temperature data was able to detect water draw events. Conservation of energy was applied to heater pipes to determine relative internal water flow rate based on transient temperature measurements. Correlations between calculated flow and actual flow were significant at a 95% confidence level. Using this methodology, a CPS water heater controller can activate existing residential storage water heaters according to occupant hot water demand. The second CPS approach integrated an open-source building simulation tool, EnergyPlus, into a CPS simulation platform developed by the National Institute of Standards and Technology (NIST). The NIST platform utilizes the High Level Architecture (HLA) co-simulation protocol for logical timing control and data communication. By modifying existing EnergyPlus co-simulation capabilities, NIST’s open-source platform was able to execute an uninterrupted simulation between a residential house in EnergyPlus and an externally connected thermostat controller. The developed EnergyPlus wrapper for HLA co-simulation can allow active replacement of traditional real-time data collection for building CPS development. As such, occupant sensors and simple home CPS product can allow greater residential participation in energy saving practices, saving up to 33% on home energy consumption nationally

Modeling and Simulation Methodologies for Digital Twin in Industry 4.0

The concept of Industry 4.0 represents an innovative vision of what will be the factory of the future. The principles of this new paradigm are based on interoperability and data exchange between dierent industrial equipment. In this context, Cyber- Physical Systems (CPSs) cover one of the main roles in this revolution. The combination of models and the integration of real data coming from the field allows to obtain the virtual copy of the real plant, also called Digital Twin. The entire factory can be seen as a set of CPSs and the resulting system is also called Cyber-Physical Production System (CPPS). This CPPS represents the Digital Twin of the factory with which it would be possible analyze the real factory. The interoperability between the real industrial equipment and the Digital Twin allows to make predictions concerning the quality of the products. More in details, these analyses are related to the variability of production quality, prediction of the maintenance cycle, the accurate estimation of energy consumption and other extra-functional properties of the system. Several tools [2] allow to model a production line, considering dierent aspects of the factory (i.e. geometrical properties, the information flows etc.) However, these simulators do not provide natively any solution for the design integration of CPSs, making impossible to have precise analysis concerning the real factory. Furthermore, for the best of our knowledge, there are no solution regarding a clear integration of data coming from real equipment into CPS models that composes the entire production line. In this context, the goal of this thesis aims to define an unified methodology to design and simulate the Digital Twin of a plant, integrating data coming from real equipment. In detail, the presented methodologies focus mainly on: integration of heterogeneous models in production line simulators; Integration of heterogeneous models with ad-hoc simulation strategies; Multi-level simulation approach of CPS and integration of real data coming from sensors into models. All the presented contributions produce an environment that allows to perform simulation of the plant based not only on synthetic data, but also on real data coming from equipments

Virtual plants in machine automation research and development

Computational product development has become the mainstream methodology in modern product development. The same trend has been visible also in research, where computational methods have gained popularity beside the traditional approach relying on theory and experimentations. The objective of this project task was to study and demonstrate a realistic approach for an industrial case to reuse existing mechanical design CAD model as the starting point and the template for mechanical system simulation using multibody system simulation, and to use this MBS model as a virtual test plant for automation and control system testing. In the report, the role of system modelling and simulation in the product process is first dis-cussed and some selected technologies, such as Modelica simulation language and Functional Mock-up Interface specification, are introduced. Then different possible implementations approaches for a test environment of the control and automation system of a multi-technical system are discussed. The latter part of report focuses on describing the selected approach for a demonstration system and its implementation. The demonstration showed that, at least for the selected case, modelling, simulation and post-processing of a multi-technical simulation system is relatively straightforward and fast with the selected tools. The demonstration gives some understanding of the process for implementing one relatively small multi-technical system but does not give realistic feedback about the challenges in industrial-scale process for virtual prototyping of large and complex systems and related data exchange and data management

Unified devs-based platform for modelling and simulation of hybrid control systems

Recent robotic research has led to different architectural approaches that support enactment of automatically synthesized discrete event controllers from user specifications over low-level continuous variable controllers. Simulation of these hybrid control approaches to robotics can be a useful validation tool for robot users and architecture designers, but presents the key challenge of working with discrete and continuous representations of the robot, its environment and its mission plans. In this work we address this challenge showcasing a unified DEVS-based hybrid simulation platform. We model and simulate the hybrid robotic software architecture of a fixed-wing UAV, including the full stack of controllers involved: discrete, hybrid and continuous. We validate the approach experimentally on a typical UAV mapping mission and show that with our unified approach we are able to achieve simulation speed-ups up to one order of magnitude above our previous Software In The Loop simulation setup

Towards a UTP semantics for modelica

We describe our work on a UTP semantics for the dynamic systems modelling language Modelica. This is a language for modelling a system’s continuous behaviour using a combination of differential algebraic equations and an event-handling system. We develop a novel UTP theory of hybrid relations, inspired by Hybrid CSP and Duration Calculus, that is purely relational and provides uniform handling of continuous and discrete variables. This theory is mechanised in our Isabelle implementation of the UTP, Isabelle/UTP, with which we verify some algebraic properties. Finally, we show how a subset of Modelica models can be given semantics using our theory. When combined with the wealth of existing UTP theories for discrete system modelling, our work enables a sound approach to heterogeneous semantics for Cyber-Physical systems by leveraging the theory linking facilities of the UTP