Beckhoff XTS Prime Mover Manufacturing Simulation

WPF + .NET 10 simulation of a Beckhoff-style XTS transport line with service-driven logic, MVVM visualization, SQLite traceability, watchdog recovery, and operator-focused HMI diagnostics.

Current Implemented Scope

• .NET target: net10.0-windows
• UI: WPF (MVVM)
• Transport: 10 movers on oval/stadium XTS track visualization
• Process cells: 4 machines (Laser Welder, Assembler, Inspector, Tester)
• Transfers: 4 robots (mover ↔ machine)
• Station chains: 18 total stations
• Persistence: SQLite (XTSFactorySim.db in output path)
• Runtime split-ready gateway boundaries:
  • IMachineGatewayService (machine commands + telemetry)
  • IDataGatewayService (history/tables/export)
  • LocalSimulationServiceGateway implements both interfaces for local mode
  • RemoteTwinCatMachineGatewayMock simulates remote machine boundary with configurable latency
• Runtime gateway mode toggle via app resources in App.xaml
• PLC/TwinCAT-style FBs:
  • Motion FBs (McPower, McMoveVelocity, McHalt, FbXtsMoverAxis)
  • Process FBs (TON, alarm latch, machine cycle sequencer)

Runtime Behavior (as implemented)

• Deterministic routing: M0 -> M1 -> M2 -> M3 -> Exit
• Machine sequencer states: Init, Ready, Run, Fault, Reset
• ET/PT timeout supervision per station (TON)
• Queue spacing on movers to reduce overlap/stacking
• Entry/Exit zone blink indicators tied to real load/unload events
• Watchdog supervision + controlled recovery:
  • machine stall
  • robot stall
  • mover stall
  • rehome/scrap fallback + root-cause alarm codes

HMI / Operator Diagnostics

Main visualization

• Beckhoff-like oval track with lane markings, seams/module look
• Entry / Load and Exit / Unload zones with live blinkers
• Machine mini-HMIs on main canvas with outward spacing for readability
• Robot transfer overlays on canvas:
  • moving robot glyphs between mover dock and machine dock points
  • animated dashed transfer lines with glow
  • direction arrowheads at active destination end

Visualization Screens

Indexed in navigation order for first-time visitors.

1) Main line visualization overview

2) Production statistics section

3) Mover live explainer section

4) Machine runtime tracking section

5) Robot transfers (mover to machine)

6) Laser welder station view

7) Assembly station view

8) Inspection station view

9) Testing station view

10) Orchestration editor screen

11) Part history inspection screen

12) Database tables view screen

13) Runtime execution logger

HMI Screen Recording

• Watch the HMI runtime recording (YouTube - Unlisted)

• Citation: YouTube (unlisted) project runtime demo — https://www.youtube.com/watch?v=cIq1iMvu8MY

Line HMI (right panel)

• Production counters and yield
• Gateway mode indicator (Local vs Remote TwinCAT Mock)
• Color/flow legend (what yellow/BaseLayer means, etc.)
• Mover live explainer:
  • state, part, next target, wait reason, position
• Machine runtime tracking:
  • action, station, part, ET/PT, fault text
• Robot transfer status and progress:
  • lane direction, stage, transfer progress, active/idle badge
• Watchdog status table (code/count/last object/time/message)

Execution Logger (bottom)

• Auto-scroll runtime log stream for movement, transfers, alarms, recoveries

SQLite Logging

Tables currently used:

• Recipes
• Parts
• PartEvents
• MachineRuns
• Results
• ProductionSnapshots
• ErrorLogs
• Alarms

Build / Run

1. Open solution in Visual Studio 2026+.
2. Restore/build (Debug | Any CPU).
3. Run with F5.
4. Use header controls:
   • START
   • STOP
   • RESET
   • Speed slider (0.1x .. 5.0x)

Continue Development on Another Laptop (Copilot-friendly)

1. Clone repo:
   • git clone https://github.com/anoop6543/XTSPrimeMoverProject
2. Open in Visual Studio with same GitHub account used for Copilot.
3. Ensure Copilot is enabled in VS.
4. Read these first:
   • README.md
   • docs/ARCHITECTURE.md
   • AGENTS.md
5. Build once before edits.
6. Prefer service/model changes first, then ViewModel, then XAML.

About “Copilot history retained”

• Retain history context by committing/pushing project docs (README, ARCHITECTURE, AGENTS) and code changes.
• Use same GitHub account + same repo branch context.
• Chat/session history itself is environment-dependent; the canonical persistent context for future Copilot runs is the repo content and these docs.

Key Files

• Engine: Services/XTSSimulationEngine.cs
• Logging: Services/SimulationDataLogger.cs
• PLC/Motion FBs: Services/TwinCAT*.cs
• Models: Models/*.cs
• View root: ViewModels/MainViewModel.cs
• Machine/data gateway contracts: Services/HmiServiceContracts.cs
• Local gateway adapter: Services/LocalSimulationServiceGateway.cs
• Remote machine mock: Services/RemoteTwinCatMock/RemoteTwinCatMachineGatewayMock.cs
• Main UI: MainWindow.xaml
• Architecture: docs/ARCHITECTURE.md
• Split-runtime plan: docs/SEPARATED-RUNTIME-PLAN.md
• Agent context: AGENTS.md