Simulation Server

The TwinEdge Simulation Server is a free OPC UA server that generates realistic industrial data for testing, development, and demos.

Download

Platform	Download	Requirements
Windows	Download (.msi)	Windows 10+
macOS	Download (.dmg)	macOS 11+
Docker	docker pull twinedge/simulation-server	Docker 20+

Features

• Realistic simulations: Industrial equipment models
• Multiple asset types: Pumps, motors, HVAC, sensors
• Configurable scenarios: Normal operation, faults, maintenance
• Standard OPC UA: Full UA specification support
• No hardware needed: Perfect for development and testing

Getting Started

Installation

Windows/macOS:

1. Download the installer
2. Run and follow prompts
3. Launch Simulation Server

Linux:

chmod +x TwinEdge-SimServer.AppImage
./TwinEdge-SimServer.AppImage

Docker:

docker run -d -p 4840:4840 twinedge/simulation-server

Starting the Server

1. Launch the Simulation Server
2. Server starts on opc.tcp://localhost:4840
3. Connect with any OPC UA client

Quick Test

Using the TwinEdge OPC UA Client:

1. Open OPC UA Client
2. Connect to opc.tcp://localhost:4840
3. Browse to Objects → Simulation
4. View simulated values updating

Simulated Assets

Centrifugal Pump

Realistic pump simulation with:

Variable	Type	Range	Unit
Vibration_X	Float	0-10	mm/s
Vibration_Y	Float	0-10	mm/s
Vibration_Z	Float	0-10	mm/s
Motor_Temperature	Float	20-120	°C
Bearing_Temperature	Float	20-100	°C
Discharge_Pressure	Float	0-20	bar
Suction_Pressure	Float	0-5	bar
Flow_Rate	Float	0-500	L/min
Motor_Current	Float	0-100	A
Motor_Speed	Int	0-3600	RPM
Run_Status	Bool	On/Off	-

Electric Motor

Motor simulation variables:

Variable	Type	Range	Unit
Stator_Temperature	Float	20-150	°C
Rotor_Temperature	Float	20-120	°C
Voltage_L1	Float	380-420	V
Voltage_L2	Float	380-420	V
Voltage_L3	Float	380-420	V
Current_L1	Float	0-100	A
Current_L2	Float	0-100	A
Current_L3	Float	0-100	A
Power_Factor	Float	0.8-1.0	-
Active_Power	Float	0-75	kW
Speed	Int	0-1800	RPM

HVAC Unit

HVAC system simulation:

Variable	Type	Range	Unit
Supply_Temperature	Float	10-30	°C
Return_Temperature	Float	15-35	°C
Humidity	Float	30-80	%
CO2_Level	Float	400-2000	ppm
Fan_Speed	Int	0-100	%
Compressor_Status	Bool	On/Off	-
Filter_Status	Int	0-100	%

Generic Sensors

Configurable sensor simulation:

Sensor Type	Variables
Temperature	Value, Unit, Status
Pressure	Value, Unit, Status
Level	Value, Unit, Status
Flow	Value, Unit, Status
Vibration	X, Y, Z, RMS

Simulation Scenarios

Normal Operation

Default scenario with stable, realistic values:

• Minor random fluctuations
• Day/night cycles
• Gradual drift

Fault Conditions

Simulate equipment faults:

Bearing Failure:

Enable: Scenarios → Pump → Bearing Failure
Effect: Vibration increases over time, temperature rises

Cavitation:

Enable: Scenarios → Pump → Cavitation
Effect: Pressure fluctuations, flow instability

Motor Overload:

Enable: Scenarios → Motor → Overload
Effect: Current spikes, temperature increase

Maintenance Events

Simulate maintenance activities:

• Scheduled shutdown
• Parameter changes
• Recovery patterns

Configuration

Server Configuration

Edit config.yaml:

server:
  port: 4840
  security:
    mode: None  # None, Sign, SignAndEncrypt
    policy: Basic256Sha256
  max_sessions: 10
  max_subscriptions: 100

Asset Configuration

Configure simulated assets:

assets:
  - id: Pump_001
    type: centrifugal_pump
    enabled: true
    update_rate_ms: 1000
    initial_state: running

  - id: Motor_001
    type: electric_motor
    enabled: true
    update_rate_ms: 500
    linked_to: Pump_001

Custom Variables

Add custom variables:

custom_variables:
  - name: CustomSensor
    node_id: ns=2;s=CustomSensor
    data_type: Float
    initial_value: 50.0
    simulation:
      type: sine
      amplitude: 10
      period_seconds: 60

Simulation Patterns

Available Patterns

Pattern	Description	Parameters
constant	Fixed value	value
random	Random within range	min, max
sine	Sinusoidal wave	amplitude, period, offset
ramp	Linear increase	start, end, duration
step	Step changes	values[], interval
noise	Gaussian noise	mean, stddev
replay	Replay CSV data	file, loop

Pattern Examples

Random with drift:

simulation:
  type: random
  min: 60
  max: 80
  drift: 0.1  # Gradual drift per minute

Sine wave:

simulation:
  type: sine
  amplitude: 5
  period_seconds: 3600  # 1 hour cycle
  offset: 65

CSV Replay:

simulation:
  type: replay
  file: historical_data.csv
  timestamp_column: time
  value_column: temperature
  loop: true

API Control

REST API

Control the simulation via REST:

# Get server status
GET http://localhost:8080/api/status

# Start/stop simulation
POST http://localhost:8080/api/simulation/start
POST http://localhost:8080/api/simulation/stop

# Trigger scenario
POST http://localhost:8080/api/scenarios/bearing_failure/enable

# Set variable value
POST http://localhost:8080/api/variables/Pump_001/Temperature
Content-Type: application/json
{"value": 85.0}

Command Line

Control via CLI:

# Start server
simserver start --port 4840

# Load configuration
simserver config load myconfig.yaml

# Trigger scenario
simserver scenario enable bearing_failure

# Stop server
simserver stop

Docker Usage

Basic Usage

docker run -d \
  --name twinedge-sim \
  -p 4840:4840 \
  -p 8080:8080 \
  twinedge/simulation-server

With Custom Config

docker run -d \
  --name twinedge-sim \
  -p 4840:4840 \
  -v $(pwd)/config.yaml:/app/config.yaml \
  twinedge/simulation-server

Docker Compose

version: '3.8'
services:
  simulation-server:
    image: twinedge/simulation-server:latest
    ports:
      - "4840:4840"
      - "8080:8080"
    volumes:
      - ./config:/app/config
    environment:
      - LOG_LEVEL=info

Use Cases

Development Testing

Test your OPC UA client code:

1. Start simulation server
2. Connect your application
3. Test read/write/subscribe operations
4. Verify error handling

Integration Testing

Automated testing scenarios:

# pytest example
def test_alarm_on_high_temperature():
    # Enable high temperature scenario
    requests.post('http://localhost:8080/api/scenarios/high_temp/enable')

    # Wait for alarm
    time.sleep(5)

    # Verify alarm triggered
    alarms = client.get_active_alarms()
    assert any(a.name == 'High Temperature' for a in alarms)

Demos and Training

Demonstrate TwinEdge features:

• Dashboard creation
• Alert configuration
• ML model training
• Report generation

Load Testing

Stress test your infrastructure:

# Start multiple instances
for i in {1..10}; do
  docker run -d -p $((4840+i)):4840 twinedge/simulation-server
done

Troubleshooting

Server Won't Start

Port in use:

# Check if port is in use
netstat -an | grep 4840

# Use different port
simserver start --port 4841

Permission denied (Linux):

# Run with sudo or change port > 1024
sudo ./simserver start
# Or
./simserver start --port 14840

Connection Issues

Cannot connect:

1. Verify server is running
2. Check firewall rules
3. Ensure correct endpoint URL

Security errors:

• Use security.mode: None for testing
• Or configure certificates properly

Performance Issues

High CPU:

• Reduce update rate
• Disable unused assets
• Limit subscription count

Support

• Source Code: github.com/twinedge/simulation-server
• Issues: GitHub Issues
• Community: discord.gg/twinedge

License

The TwinEdge Simulation Server is open source under the MIT License.

Next Steps

• OPC UA Client - Connect to the simulation
• Data Sources - Add to TwinEdge platform
• Installation - Deploy TwinEdge Edge