Model-Based Virtual Components in Event-Based Controls: Linking the FMI and IEC 61499

Various development and validation methods for cyber-physical systems such as Controller-Hardware-in-the-Loop (C-HIL) testing strongly benefit from a seamless integration of (hardware) prototypes and simulation models. It has been often demonstrated that linking discrete event-based control systems and hybrid plant models can advance the quality of control implementations. Nevertheless, high manual coupling efforts and sometimes spurious simulation artifacts such as glitches and deviations are observed frequently. This work specifically addresses these two issues by presenting a generic, standard-based infrastructure referred to as virtual component, which enables the efficient coupling of simulation models and automation systems. A novel soft real-time coupling algorithm featuring event-accurate synchronization by extrapolating future model states is outlined. Based on considered standards for model exchange (FMI) and controls (IEC 61499), important properties such as real-time capabilities are derived and experimentally validated. Evaluation demonstrates that virtual components support engineers in efficiently creating C-HIL setups and that the novel algorithm can feature accurate synchronization when conventional approaches fail.