Process Simulation Development with IEC 61499 for Runtime Execution

Pasindu Padmathilaka; Pranay Jhunjhunwala; Valeriy Vyatkin

doi:10.1109/ETFA65518.2025.11205643

Process Simulation Development with IEC 61499 for Runtime Execution

Pasindu Padmathilaka^*
, Pranay Jhunjhunwala^*
, Valeriy Vyatkin^*

^*Corresponding author for this work

Luleå University of Technology

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

1 Citation (Scopus)

4 Downloads (Pure)

Abstract

This paper proposes a method to build plant simulation models by means of IEC 61499 to execute them directly within PLC concurrently with control. This addresses the problems of cost, time, and incompatibility associated with developing plant simulation models using separate software. The proposed approach improves testing and troubleshooting and provides advanced data processing within the control system. It is inspired by Model-View-Control design pattern and was demonstrated with a conveyor system use case. The plant simulation model can function as a real-time monitor or operate in simulation mode.

Original language	English
Title of host publication	2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings
Editors	Luis Almeida, Marina Indria, Mario de Sousa, Antonio Visioli, Mohammad Ashjaei, Pedro Santos
Publisher	IEEE
Number of pages	8
ISBN (Electronic)	979-8-3315-5383-8
DOIs	https://doi.org/10.1109/ETFA65518.2025.11205643
Publication status	Published - 2025
MoE publication type	A4 Conference publication
Event	IEEE International Conference on Emerging Technologies and Factory Automation - Porto, Portugal Duration: 9 Sept 2025 → 12 Sept 2025 Conference number: 30

Publication series

Name	IEEE International Conference on Emerging Technologies and Factory Automation, ETFA
ISSN (Print)	1946-0740
ISSN (Electronic)	1946-0759

Conference

Conference	IEEE International Conference on Emerging Technologies and Factory Automation
Abbreviated title	ETFA
Country/Territory	Portugal
City	Porto
Period	09/09/2025 → 12/09/2025

Funding

This work was supported, in part, by project I-SWARM X (p/n 411061), funded by Vacon Oy, SmartGrid 2.0 funded by Business Finland, CAFE (p/n 13363691) and Multi-energy VPP (p/n 13348415), both funded by the Research Council of Finland.

Keywords

Digital Twins
IEC 61499
Model-View-Control
Plant Simulation Models

Access to Document

10.1109/ETFA65518.2025.11205643

Process_simulation_development_with_IEC_61499_for_runtime_executionAccepted author manuscript, 3.81 MB

Cite this

Padmathilaka, P., Jhunjhunwala, P., & Vyatkin, V. (2025). Process Simulation Development with IEC 61499 for Runtime Execution. In L. Almeida, M. Indria, M. de Sousa, A. Visioli, M. Ashjaei, & P. Santos (Eds.), 2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA). IEEE. https://doi.org/10.1109/ETFA65518.2025.11205643

Padmathilaka, Pasindu ; Jhunjhunwala, Pranay ; Vyatkin, Valeriy. / Process Simulation Development with IEC 61499 for Runtime Execution. 2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings. editor / Luis Almeida ; Marina Indria ; Mario de Sousa ; Antonio Visioli ; Mohammad Ashjaei ; Pedro Santos. IEEE, 2025. (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA).

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title = "Process Simulation Development with IEC 61499 for Runtime Execution",

abstract = "This paper proposes a method to build plant simulation models by means of IEC 61499 to execute them directly within PLC concurrently with control. This addresses the problems of cost, time, and incompatibility associated with developing plant simulation models using separate software. The proposed approach improves testing and troubleshooting and provides advanced data processing within the control system. It is inspired by Model-View-Control design pattern and was demonstrated with a conveyor system use case. The plant simulation model can function as a real-time monitor or operate in simulation mode.",

keywords = "Digital Twins, IEC 61499, Model-View-Control, Plant Simulation Models",

author = "Pasindu Padmathilaka and Pranay Jhunjhunwala and Valeriy Vyatkin",

note = "Publisher Copyright: {\textcopyright} 2025 IEEE.; IEEE International Conference on Emerging Technologies and Factory Automation, ETFA ; Conference date: 09-09-2025 Through 12-09-2025",

year = "2025",

doi = "10.1109/ETFA65518.2025.11205643",

language = "English",

series = "IEEE International Conference on Emerging Technologies and Factory Automation, ETFA",

publisher = "IEEE",

editor = "Luis Almeida and Marina Indria and \{de Sousa\}, Mario and Antonio Visioli and Mohammad Ashjaei and Pedro Santos",

booktitle = "2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings",

address = "United States",

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Padmathilaka, P, Jhunjhunwala, P & Vyatkin, V 2025, Process Simulation Development with IEC 61499 for Runtime Execution. in L Almeida, M Indria, M de Sousa, A Visioli, M Ashjaei & P Santos (eds), 2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings. IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, IEEE, IEEE International Conference on Emerging Technologies and Factory Automation, Porto, Portugal, 09/09/2025. https://doi.org/10.1109/ETFA65518.2025.11205643

Process Simulation Development with IEC 61499 for Runtime Execution. / Padmathilaka, Pasindu; Jhunjhunwala, Pranay; Vyatkin, Valeriy.
2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings. ed. / Luis Almeida; Marina Indria; Mario de Sousa; Antonio Visioli; Mohammad Ashjaei; Pedro Santos. IEEE, 2025. (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA).

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

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T1 - Process Simulation Development with IEC 61499 for Runtime Execution

AU - Padmathilaka, Pasindu

AU - Jhunjhunwala, Pranay

AU - Vyatkin, Valeriy

N1 - Conference code: 30

PY - 2025

Y1 - 2025

N2 - This paper proposes a method to build plant simulation models by means of IEC 61499 to execute them directly within PLC concurrently with control. This addresses the problems of cost, time, and incompatibility associated with developing plant simulation models using separate software. The proposed approach improves testing and troubleshooting and provides advanced data processing within the control system. It is inspired by Model-View-Control design pattern and was demonstrated with a conveyor system use case. The plant simulation model can function as a real-time monitor or operate in simulation mode.

AB - This paper proposes a method to build plant simulation models by means of IEC 61499 to execute them directly within PLC concurrently with control. This addresses the problems of cost, time, and incompatibility associated with developing plant simulation models using separate software. The proposed approach improves testing and troubleshooting and provides advanced data processing within the control system. It is inspired by Model-View-Control design pattern and was demonstrated with a conveyor system use case. The plant simulation model can function as a real-time monitor or operate in simulation mode.

KW - Digital Twins

KW - IEC 61499

KW - Model-View-Control

KW - Plant Simulation Models

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U2 - 10.1109/ETFA65518.2025.11205643

DO - 10.1109/ETFA65518.2025.11205643

M3 - Conference article in proceedings

AN - SCOPUS:105021836512

T3 - IEEE International Conference on Emerging Technologies and Factory Automation, ETFA

BT - 2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings

A2 - Almeida, Luis

A2 - Indria, Marina

A2 - de Sousa, Mario

A2 - Visioli, Antonio

A2 - Ashjaei, Mohammad

A2 - Santos, Pedro

PB - IEEE

T2 - IEEE International Conference on Emerging Technologies and Factory Automation

Y2 - 9 September 2025 through 12 September 2025

ER -

Padmathilaka P, Jhunjhunwala P, Vyatkin V. Process Simulation Development with IEC 61499 for Runtime Execution. In Almeida L, Indria M, de Sousa M, Visioli A, Ashjaei M, Santos P, editors, 2025 IEEE 30th International Conference on Emerging Technologies and Factory Automation, ETFA 2025 - Proceedings. IEEE. 2025. (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA). doi: 10.1109/ETFA65518.2025.11205643

Process Simulation Development with IEC 61499 for Runtime Execution

Abstract

Publication series

Conference

Funding

Keywords

Access to Document

Other files and links

Fingerprint

CAFE: Conscious agents as a foundation for a collaborative factory of the future

Multi-Energy VPP: Adaptive Multi-Energy Virtual Power Plant for a Complex of Buildings

Cite this

Process Simulation Development with IEC 61499 for Runtime Execution

Abstract

Publication series

Conference

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Projects

CAFE: Conscious agents as a foundation for a collaborative factory of the future

Multi-Energy VPP: Adaptive Multi-Energy Virtual Power Plant for a Complex of Buildings

Cite this