Stageproject Atlas Copco - Modbus TCP Simulatie

Stageproject Atlas Copco — Modbus TCP Simulatie

Tijdens mijn stage bij Atlas Copco ontwikkelde ik Simulator_Chef v1, een geautomatiseerd testplatform voor Modbus TCP. Het systeem simuleert een volledige industriële PLC, schrijft testwaarden naar alle measurement points, en verifieert automatisch de correctheid van data op drie niveaus: Simulator, SBP Client en Cloud.

De volledige dataketen en verificatie-pipeline:

Translation File (JSON) → CLI Menu → Modbus Simulator → SBP Client → Cloud
Python → PyModbus → Async TCP Server/Client

Het platform valideert onder andere:

de correctheid van geschreven vs. gelezen Modbus registerwaarden;
expected value berekening via een volledige functieketen (scale, offset, combine, bit_cp);
endianness verificatie (B2B, L2L, B2L, L2B) voor 32-bit registers;
BIT_CP en B16 bit-positie logica inclusief inversie;
unit conversies (°C→K, bar→Pa, mbar→Pa);
cloud data doorvoer en upload rule timing via de Coiote API.

Alle testresultaten worden gestructureerd opgeslagen in CSV-rapporten en JSON-verificatiebestanden. Het systeem ondersteunt meerdere upload rule configuraties en biedt een interactief CLI-menu voor volledige configuratie zonder code-aanpassingen.

Het project is verpakt als standalone executable (Simulator_Chef.exe) via PyInstaller, inclusief alle afhankelijkheden, SSL-certificaten en configuratiebestanden — klaar voor deployment op elke Windows-machine zonder Python-installatie.

[13:03:14.055] [INFO] Waiting for SBP connection...
[13:03:14.083] [INFO] Triggering SBP connection refresh (SBP_CONE_SIM)...
Connection to SBP

--- (-_-) OK! let the magic begin! (-_-)---

[13:03:19.123] [INFO] Connection detected! Resuming in 4s..

 _     _     _     _     _     _     _     _     _     _
(o>   (o>   (o>   (o>   (o>   (o>   (o>   (o>   (o>   (o>
//\   //\   //\   //\   //\   //\   //\   //\   //\   //\
V_/_  V_/_  V_/_  V_/_  V_/_  V_/_  V_/_  V_/_  V_/_  V_/_


[13:03:23.189] [INFO] Starting background client fetch thread...
[13:03:23.189] [INFO] Loading JSON config directly: C:\Users\

Modulaire Simulatie Architectuur

Ontwerp en implementatie van een volledig modulair Modbus TCP testplatform met 15+ Python-modules: orchestrator, mapper, calculator, test runner, report generator en verificatie pipeline.

Interactief CLI Menu & Configuratie

Volledig interactief command-line menu met persistente configuratie (JSON save/load), 5 upload rule modes, VIP menu met SSH/SCP push functionaliteit naar de SBP.

Drie-Niveau Verificatie Pipeline

Automatische vergelijking op drie niveaus: SIM↔SBP (Modbus TCP), SBP↔Cloud (Coiote API), en multi-stage cloud verificatie met upload rule timing validatie.

MPCalculator: Expected Value Engine

Berekening van expected values via een volledige validatieketen: scale, offset, combine (S32/F32), bit_cp, inversie en VMP operaties (add/sub/prod/div). Simuleert exact de SBP client functieketen.

Setup & Deployment

PyInstaller packaging als standalone executable. Automatische netwerkconfiguratie, vereisten-check en guided setup — klaar voor deployment op elke Windows-machine zonder Python-installatie.

Coiote Cloud Verificatie

Automatische multi-stage cloud verificatie via de Coiote IoT API. Device ID validatie, API mode selectie (BULK/PER_MP), en geconsolideerde rapporten met per-stage tracking.

Het Operationele Eindresultaat

Het platform test alle measurement points volledig automatisch, genereert gestructureerde rapporten en valideert data-integriteit van simulator tot cloud — in één commando.

Realisatie-Stappenplan

1. Analyse & Protocol Studie

Studie van het Modbus TCP protocol, register adres ranges (Coil, Discrete Input, Input/Holding Register), datatypes (S16, U32, F32, BIT_CP, B16) en endianness varianten. Analyse van de SBP JSON-configuratie structuur.

2. Modulair Framework Ontwerp

Ontwerp van een modulaire architectuur met 15+ Python-modules: orchestrator, connection manager, MP mapper, test runner, report generator, data generator, bit logic engine en expected value calculator.

3. Simulatie & Verificatie Engine

Implementatie van de PyModbus async client/server, conflict detectie (SHARED_ADDRESS), collision handling, en een drie-niveau verificatie pipeline: SIM↔SBP, SBP↔Cloud, en multi-stage cloud verificatie.

4. CLI Menu & Automatisering

Ontwikkeling van een interactief CLI-menu met configuratie persistentie, 5 upload rule modes, SSH/SCP push functionaliteit, en volledige pipeline automatisering — van test tot cloud verificatie in één run.

5. Packaging & Documentatie

PyInstaller packaging als standalone executable met alle dependencies. Volledige technische documentatie, handover dossier en changelog. Release builder voor geautomatiseerde distributie.

6. Test Fase & Demo

Live testing met alle measurement points op echte SBP hardware. Demo-presentaties aan development engineers, iteratieve bugfixes op basis van real-world feedback (S32 combine bug, conflict detectie, latency issues). Validatie van de volledige pipeline: simulatie → verificatie → cloud.

De kracht van dit project lag in het combineren van diepgaande protocol-kennis met software engineering — resulterend in een testplatform dat alle measurement points volledig automatisch kan valideren van simulator tot cloud.

Simulator_Chef CLI — Hoofdmenu

                        
╔══════════════════════════════════════════════════════════════════════╗
║                   MODBUS SIMULATOR — SETUP INFO                      ║
╚══════════════════════════════════════════════════════════════════════╝

REQUIRED TOOLS:
──────────────────────────────────────────────────────────────────────
  1. Modbus_Simulator_v2.2.0.exe (or v1)
     → Desktop simulator with REST API + WebSocket interface
  2. SBP Commissioning Tool  (version ≥ 1.8)
     → For configuring the SBP device

NETWORK CONFIGURATION:
──────────────────────────────────────────────────────────────────────
  The PC, Simulator, and SBP device must be on the same subnet.
  If you use the default settings, set your network adapter to:
  Static IP: 192.168.100.40

  ┌──────────────────┐    ┌─────────────────────────────┐    ┌────────────────────────┐
  │   PC             │    │   SIMULATOR                 │    │   SBP DEVICE (TCP)     │
  │  192.168.100.40  │◄──►│  192.168.100.40 : port 502  │◄──►│  192.168.100.40 : 502  │
  └──────────────────┘    └─────────────────────────────┘    └────────────────────────┘

IMPORTANT:
──────────────────────────────────────────────────────────────────────
  When the register/translation file is changed in the simulator,
  it must also be updated in the SBP via the Commissioning Tool.
 _
(o>   Dont open de Live SBP Commissioning Tool View upload measurements you kan do thes after the test run.
//\
V_/_


    Press Enter to continue...                            
                            
                            
                            
╔══════════════════════════════════════════════════════════════╗
║              MODBUS SIMULATOR — MAIN MENU                    ║
╚══════════════════════════════════════════════════════════════╝
──────────────────────────────────────────────────────────────
  Translation File :  2026.json
  Network          :  192.168.100.40 : 502
  Iterations       :  1
  Bit Mode         :  ALTERNATING
  Report Base Dir  :  .../Simulator_Chef_v1/ReportSIM&SBP
──────────────────────────────────────────────────────────────

  [1]  Network Settings
  [2]  Select Translation File
  [3]  Test Settings
  [4]  Report Settings
  [S]  START TEST
  [Q]  Quit

  Select [1/2/3/4/S/Q]: █

Test Settings

═══ TEST SETTINGS ═══
────────────────────────────────
 [1] Test Iterations      = 1
 [2] Bit Value Mode       = ALTERNATING
 [3] Max Tests/Category   = 180
 [4] Keep Connection (min)= 400
 [5] Troubleshooting Mode = OFF
 [6] Fetch SBP Client Logs= ON
 [7] Auto Verify SIM<>SBP= ON
 [8] Skip Unknown Rules   = OFF
 [9] Relative Tolerance   = OFF
 [10] Auto Cloud Verify   = ON (PER_MP)
 [11] Test per Upload Mode= ALL

 Edit setting [1-11/Enter]: █

Bevestiging

────────────────────────────────
 CONFIRMATION REQUIRED
 Translation file : 2026.json
 Device IP     : 192.168.100.40
 Port          : 502
 Send modes
 Base mode     : (Fast Mode Vis)
 Cloud Verify  : ON
 Device ID     : WCnxBf...NDgVPQ

 Is the SBP configured with
 this same register file,
 IP, port and send modes?
 [Y/N]: █

Verificatie Report Output


════════════════════════════════════════════════════════════
COIOTE CLOUD VERIFICATION — CONSOLIDATED REPORT
════════════════════════════════════════════════════════════
Source: Verify_SBPvsSIM_2026-03-16_10-25-56.json
Stages: 4

SOURCE DATA OVERVIEW (Verify_SBPvsSIM)
────────────────────────────────────────────────────────────
  Total Tested:     110
  SBP Matches:      109
  SBP Missing:      0
  SBP Mismatches:   0
  Success Rate:     100.0%

STAGE 1: Short Term (0-10 min)
  Timestamp:    2026-03-16_10-40-57
──────────────────────────────────────────────────
  MPs checked:     109/109
  Found in cloud:  109
  Match:           107
  Mismatch:        2
  Missing:         0
  Rule compliant:  11
  Rule violations: 98

STAGE 3: 1 Hour Check
  Timestamp:    2026-03-16_11-25-56
  
  MPs TABLE (per-stage cloud status)
────────────────────────────────────────────────────────────────────────────────────────────────────────────
  MP       Expected         Upload Rule               @short     @mid       @1hour     @final     Final     
  ──────────────────────────────────────────────────────────────────────────────────────────────────────────    
  507      11140.0          5 SEC (On Change)         MATCH      -          -          -          MATCH     
  509      91900.0          0 SEC (On Change)         MATCH      -          -          -          MATCH █

CLIENT MATCHED vs CLOUD — Short Term (0-10 min) (152 MPs)
────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────
  ──────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────
  MP       Expected         SBP              Cloud            Upload Rule            Bit Pos  Sim Time   SBP Time               Update (UTC)             Upload (CET)           SBP      Cloud  
  ──────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────
  ****     1400000.0        1400000.0        1400000.0        5 SEC (On Change)      -        22:27:27   2026-03-11 22:27:27    2026-03-11T21:27:27.00   2026-03-11 22:27:27    OK       MATCH  
  ****     3200000.0        3200000.0        3200000.0        5 SEC (On Change)      -        22:27:27   2026-03-11 22:27:32    2026-03-11T21:27:32.00   2026-03-11 22:27:32    OK       MATCH  
  ****     2200000.0        2200000.0        2200000.0        5 SEC (On Change)      -        22:27:27   2026-03-11 22:27:32    2026-03-11T21:27:32.00   2026-03-11 22:27:32    OK       MATCH  
  ****     5000000.0        5000000.0        5000000.0        5 SEC (On Change)      -        22:27:27   2026-03-11 22:27:32    2026-03-11T21:27:32.00   2026-03-11 22:27:32    OK       MATCH

PyModbus Modbus TCP Python 3.11 Coiote API CSV/JSON

Workflow: Van Config tot Cloud Verificatie

JSON Config Async I/O TCP/IP SSL/TLS REST API

╔══════════════════════════════════════════════════════════════════════╗ ║ MODBUS SIMULATOR — SETUP INFO ║ ╚══════════════════════════════════════════════════════════════════════╝ REQUIRED TOOLS: ────────────────────────────────────────────────────────────────────── 1. Modbus_Simulator_v2.2.0.exe (or v1) → Desktop simulator with REST API + WebSocket interface 2. SBP Commissioning Tool (version ≥ 1.8) → For configuring the SBP device NETWORK CONFIGURATION: ────────────────────────────────────────────────────────────────────── The PC, Simulator, and SBP device must be on the same subnet. If you use the default settings, set your network adapter to: Static IP: 192.168.100.40 ┌──────────────────┐ ┌─────────────────────────────┐ ┌────────────────────────┐ │ PC │ │ SIMULATOR │ │ SBP DEVICE (TCP) │ │ 192.168.100.40 │◄──►│ 192.168.100.40 : port 502 │◄──►│ 192.168.100.40 : 502 │ └──────────────────┘ └─────────────────────────────┘ └────────────────────────┘ IMPORTANT: ────────────────────────────────────────────────────────────────────── When the register/translation file is changed in the simulator, it must also be updated in the SBP via the Commissioning Tool. _ (o> Dont open de Live SBP Commissioning Tool View upload measurements you kan do thes after the test run. //\ V_/_ Press Enter to continue...

╔══════════════════════════════════════════════════════════════════════╗ ║ MODBUS SIMULATOR — MAIN MENU ║ ╚══════════════════════════════════════════════════════════════════════╝ ────────────────────────────────────────────────────────────────────── Translation File : 2026.json Network : 192.168.100.40 : 502 Iterations : 1 Bit Mode : ALTERNATING Report Base Dir : C:***********Simulator_Chef_v1\ReportSIM&SBP ────────────────────────────────────────────────────────────────────── ═══ SIMULATOR_CHEF v1 ═══ [1] Network Settings IP + poort (default 192.168.100.40:502) [2] Select Translation File Auto-detect .json/.xlsm [3] Test Settings Iteraties, Bit Mode, VMP, Max Tests, Troubleshooting, Cloud Verify, Upload Mode Filter [4] Report Settings Basismap, kolommen ON/OFF, delete-after-test [S] Start Test Bevestigingsscherm met alle instellingen [Q] Quit

Select [1/2/3/4/S/Q]: 2026 ╔═══════════════════════════════════════════════╗ ║ 🔧 VIP ENGINEER MENU 🔧 ║ ╚═══════════════════════════════════════════════╝ [1] Switch Upload Rules Mode Current: visualizationConfig → Wissel tussen 5 upload rule configuraties [2] Push Visualization Config → SBP Mode: Normal → SSH/SCP push van visualization mode naar SBP device [3] Push Fast Mode Config → SBP Mode: Fast (2631 MPs @ 5 SEC) → SSH/SCP push van fast mode configuratie naar SBP [B] ← Back to Main Menu Select [1/2/3/B]: █

═══ NETWORK SETTINGS ═══ Current: 192.168.100.40:502 [1] Use default (192.168.100.40 : 502) [2] Use custom IP (192.168.100.? : 502) [Enter] Keep current Select [1/2/Enter]: █

═══ REGISTER FILE ═══ Current: 2026.json [ 1] 2026.json (.JSON) ◄ current [ 2] FC03_T08 - Copy.json (.JSON) [ 3] FC04_T08 - Copy.json (.JSON) [ 4] SBP - FC01_T08.json (.JSON) [ 5] SBP - FC02_T08.json (.JSON) [ 6] SBP - FC03_T08.json (.JSON) [ 7] SBP - FC04.json (.JSON) [ 8] SBP -ZH_Wuxi...T08.xlsm.json (.JSON) [ 9] 2026.xlsm (.XLSM) [10] FC03_T08 - Copy.xlsm (.XLSM) ... [16] SBP -ZH_Wuxi...T08.xlsm (.XLSM) Select [1-16/Enter]: █

═══ TEST SETTINGS ═══ ────────────────────────────────────────────────────────── [1] Test Iterations = 1 [2] Bit Value Mode = ALTERNATING [3] Max Tests/Category = 180 [4] Keep Connection (min) = 400 [5] Troubleshooting Mode = OFF [6] Fetch SBP Client Logs = ON [7] Auto Verify SIM<>SBP = ON [8] Skip Unknown Rules = OFF [9] Relative Tolerance = OFF [10] Auto Cloud Verify = ON (PER_MP) [11] Test per Upload Mode = ALL (no filter) Edit setting [1-11/Enter]: █

Current Device ID: ********************************* [Enter] Keep current, or paste a new one Device ID: Validating Device ID with Coiote API... ✓ Device ID valid — device found in cloud v Auto Cloud Verify: ON API Mode: [A] cache********* (BULK) = OFF [B] device************* (PER_MP) = ON [Enter] Keep current API settings Toggle [A/B/Enter]: █

=== REPORT SETTINGS === ────────────────────────────────────────────────────────── [1] Report base directory = .../ReportSIM&SBP Per-run subfolder: <translationfile>_<datetime>/ [2] Delete ModbusReport after = NO (keep reports) [3] Report columns SIM vs SBP = 12/16 visible [4] Report columns Cloud = 12/14 visible [5] Delete SBP_Log after verify = YES Edit setting [1-5/Enter]: █

Report .txt Columns (SIM vs SBP): [ 1] ON MP (w: 6) [ 2] ON Raw Addr (w: 8) [ 3] ON Reg Type (w:10) [ 4] ON MP Type (w: 7) [ 5] ON Bit (w:10) [ 6] OFF Round S (w: 7) [ 7] OFF Round R (w: 7) [ 8] ON Sent (w:10) [ 9] ON Expected (w:20) [10] ON Received (w:10) [11] OFF Latency (w: 8) [12] ON Status (w:10) [13] OFF Reason (w:25) [14] ON Description (w:32) [15] ON Exp Unit (w:10) [16] ON Bit Name (w:20)

Cloud Report .txt Columns (Coiote): [ 1] ON MP (w: 8) [ 2] ON Expected (w:16) [ 3] ON SBP (w:16) [ 4] ON Cloud (w:16) [ 5] ON Upload Rule (w:22) [ 6] ON Bit Pos (w: 8) [ 7] ON Sim Time (w:10) [ 8] ON SBP Time (w:22) [ 9] ON Update (UTC) (w:24) [10] ON Upload (CET) (w:22) [11] OFF SBP (w: 8) [12] ON Cloud (w:12) [13] ON First After (w:18) [14] OFF Latest Value (w:18)

────────────────────────────────────────────────────────── CONFIRMATION REQUIRED Translation file : 2026.json Device IP : 192.168.100.40 Port : 502 Send modes Base mode : (Fast Mode Vis) Cloud Verify : ON Device ID : WCnxBfHEVYSPVF1NP211144558xWtctzNDgVPQ Is the SBP configured with this same register file, IP, port and send modes? [Y/N]: █

Current Device ID: WCnxBfHEVYSPVF1NP211144558xWtctzNDgVPQ Validating Device ID with Coiote API... ✓ Device ID valid — device found in cloud v Auto Cloud Verify: ON API Mode: [A] cache********* (BULK) = OFF [B] device************* (PER_MP) = ON Toggle [A/B/Enter]: █

Type	Grootte	Beschrijving
S16	1 register	Signed 16-bit integer
U16	1 register	Unsigned 16-bit integer
S32	2 registers	Signed 32-bit (endianness)
F32	2 registers	IEEE 754 floating point
BIT_CP	1 bit	Bit Copy source → destination
B16	16 bits	16-bit bitmap (meerdere MPs)

Type

Grootte

Beschrijving

S16

1 register

Signed 16-bit integer

U16

1 register

Unsigned 16-bit integer

S32

2 registers

Signed 32-bit (endianness)

F32

2 registers

IEEE 754 floating point

BIT_CP

1 bit

Bit Copy source → destination

B16

16 bits

16-bit bitmap (meerdere MPs)

Input	Factor/Offset	Output
bar	× 100.000	Pa
mbar	× 100	Pa
°C	+ 273.15	K (Kelvin)

Input

Factor/Offset

Output

bar

× 100.000

mbar

× 100

°C

+ 273.15

K (Kelvin)

╔══════════════════════════════════════════════════════════╗ ║ MODBUS SIMULATOR — SETUP INFO ║ ╚══════════════════════════════════════════════════════════╝ REQUIRED TOOLS: 1. Modbus_Simulator_v2.2.0.exe (or v1) → Desktop simulator with REST API + WebSocket 2. SBP Commissioning Tool (version ≥ 1.8) → For configuring the SBP device NETWORK CONFIGURATION: The PC, Simulator, and SBP device must be on the same subnet. Static IP: 192.168.100.40 ┌─────────────┐ ┌──────────────────┐ ┌─────────────────┐ │ PC │◄───►│ SIMULATOR │◄───►│ SBP DEVICE(TCP) │ │ .100.40 │ │ .100.40 : 502 │ │ .100.40 : 502 │ └─────────────┘ └──────────────────┘ └─────────────────┘ Press Enter to continue...

release/Simulator_Chef_v1/ ├── Simulator_Chef.exe # Hoofdprogramma ├── Modbus_Simulator_v2.2.0.exe # Desktop simulator ├── README.md # Quick start guide ├── translation_files/ # MP configuratie └── ReportSIM&SBP/ # Output rapporten

Current Device ID: WCnxBfHEVYSPVF1NP211144558xWtctzNDgVPQ Validating Device ID with Coiote API... ✓ Device ID valid — device found in cloud v Auto Cloud Verify: ON API Mode: [A] cache****** (BULK) = OFF [B] devi******** (PER_MP) = ON Toggle [A/B/Enter]: █

Stage	Timing	Controleert
Short Term	Na 15 min	5 SEC tot 5 MIN rules
Mid Term	Na 30 min	+ 10 MIN, 30 MIN rules
1 Hour	Na 60 min	+ 1 HOUR rules
Final Sweep	Op verzoek	Alle ongematchte MPs

Stage

Timing

Controleert

Short Term

Na 15 min

5 SEC tot 5 MIN rules

Mid Term

Na 30 min

+ 10 MIN, 30 MIN rules

1 Hour

Na 60 min

+ 1 HOUR rules

Final Sweep

Op verzoek

Alle ongematchte MPs

══ TEST PER UPLOAD MODE ══ Scanning 2026.json... ✓ Found 9 upload rules (156 MPs total) Upload Rules (fastest → slowest): [ 1] ON 0 SEC (On Change) (9 MPs) [ 2] ON 5 SEC (On Change) (6 MPs) [ 3] ON 5 MIN (>0.5%) (2 MPs) [ 4] ON 5 MIN (>0.5°C) (32 MPs) [ 5] ON 5 MIN (>1%) (25 MPs) [ 6] ON 5 MIN (On Change) (31 MPs) [ 7] ON 30 MIN (Always) (1 MPs) [ 8] ON 1 HOUR (Always) (3 MPs) [ 9] ON UNKNOWN / DEFAULT (47 MPs) Selected: 156/156 MPs [A] Select ALL [N] Select NONE Toggle [1-9/A/N/Enter]: █