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TcForge plant simulation

This package models physical counterparts to TcForge devices. The PLC remains the controller. Pure plant models, IO transports and scenario orchestration are separate so the same models can be used offline and later against TwinCAT.

Implemented: three-cylinder assembly-cell travel, jams and sensor overrides; part-presence and discharge photoeyes; bounded pressure and height analog responses; ordered read/model/write exchange; JSONL traces; a read-only ADS target probe; and live PLC functional scenarios. No Redwood source or SPT code is copied into this package. The Redwood prototype informed the separation of physics and IO adapters.

Run locally

From the repository root:

python -m venv artifacts/sim-venv
artifacts/sim-venv/Scripts/python.exe -m pip install --upgrade pip
artifacts/sim-venv/Scripts/python.exe -m pip install -e "./python[ads]"
artifacts/sim-venv/Scripts/python.exe -m unittest discover -s python/tests -v
artifacts/sim-venv/Scripts/python.exe -m tcforge_sim --trace artifacts/cylinder-trace.jsonl
artifacts/sim-venv/Scripts/python.exe -m tcforge_sim.ads --target 192.168.1.108.1.1 --port 853

Offline execution uses explicit simulated time. It does not execute Structured Text or prove PLC behavior. The cylinder assumes a double-solenoid plant that holds position with both coils off. Configure a different model for spring-return valves, pressure decay, inertia or a different de-energized response. Shutdown confirmation must have its own plant model; it cannot be inferred from coil bits.

The offline runner rejects duplicate/restarted output frames and stops after an uncertain write. The live runner uses a PLC-owned frame exchange, exclusive session, boot identity and watchdog. It advances physics using wall-clock time and requires explicit recovery after lost communication.

The C# transport validates the simulation identity and RPC signatures at startup, then retains method handles for its connection lifetime. Each RPC uses one ADS read/write round trip. A method failure terminates the transport; it does not refresh a handle and replay an uncertain command. Identity/signature discovery has a separate 30-second startup deadline before any IO session is claimed. This does not relax the 200 ms live scheduling or 150 ms frame-confirmation budgets.

Use scripts/benchmark_simulation_rpc.py --target <AMS-Net-ID> --port 854 --transport artifacts/simulation-rpc/SimulationRpc.exe --output artifacts/rpc-timing.json to measure read-only snapshot latency. This benchmark does not qualify cyclic IO.

Live assembly testing

Build/install TcForge, build the narrow ADS RPC transport, and activate the isolated simulation on a dedicated runtime using the commands in the simulation guide. Activation replaces that target's configuration. The standalone simulation PLC uses port 854; the TcUnit composition also includes the bridge at port 853.

artifacts/sim-venv/Scripts/python.exe -m tcforge_sim.functional --target 192.168.1.108.1.1 --port 854 --transport artifacts/simulation-rpc/SimulationRpc.exe --output artifacts/assembly-e2e

The suite runs the actual PLC locate, press, inspect and eject recipe plus Stop/Abort, jam, sensor contradiction, bad quality, blocked discharge, shutdown confirmation, watchdog and reconnect recovery scenarios. It writes assembly-trace.jsonl and assembly-junit.xml and exits nonzero when a scenario fails. PLC restart and physical IO acceptance remain tracked in PROGRESS.md.

Generic closed-loop control test

The Testing PLC on port 853 also contains a bench-only PID fixture. Its framed ADS surface has no physical IO binding. The Python runner uses the existing first-order analog model as a generic process, feeds its PV and quality to the PLC, and advances the model from the PLC's CV. It checks convergence, loss and recovery of sensor quality, feed-watchdog shutdown and explicit disable.

artifacts/sim-venv/Scripts/python.exe -m tcforge_sim.control_loop --target <AMS-Net-ID> --port 853 --output artifacts/control-loop-bench

The payload is written before its frame number; a lost acknowledgement ends that transport session without replay. Results are written to control-loop.jsonl and control-loop-junit.xml. This test exercises PLC control against simulated physics, not real fieldbus or actuator behavior.