CHP, banks and trees on a scale of 160 to 1: the history of creating a layout for the Standoff cyber battle

The Gramota.ru portal claims that «A model is an object that accurately reproduces another object in a reduced size or full size».

But this is more about the models that can be seen in museums, exhibitions, apartment sales offices, and so on. In our case, the models presented at the Standoff cyber battle are complex hardware and software systems, each of which, in addition to the visible outer part, consists of dozens of controllers and microcomputers (some of which were developed and manufactured specifically for us), many different types of engines, screens, several kilometers of wiring. Various network, power, and logical devices, combined together, create a unique and spectacular model that simulates the life of a state, with which the participants of the cyber battle interact.

How it all started

The model first appeared at the competition in 2016 and has since become an integral part of it, constantly increasing, improving, acquiring details, industries, new process visualizations, and Easter eggs. By 2022, the model was a monstrous structure consisting of 14 hexagonal models, which together formed the "State F".

In 2023, the idea arose to create new models with a different concept. Now they have a square shape, the size has become larger, each is installed separately, allowing you to approach from any side and examine in detail everything that happens on the model.

The first five models of the new concept were unveiled in May 2024 at the Standoff 13 cyber battle, which took place in "Luzhniki". Here, the concept of "Two States" was also applied: the participant teams were divided between "State F" with old models and "State S" with new samples.

How and why we create the model

The development of each layout begins with the question: what do we want to show? For this, we and colleagues from other departments study the infrastructure not only of our state, but also of other countries, we try to reproduce them, since it is reckless to take separate industries and focus on something specific — everyone is attacked :) In some cases, we study the local infrastructure.

When the target industry for the layout is selected, brainstorming begins: we try to understand how to present different infrastructure objects on it. The main generator of ideas here is the design group. The team carefully analyzes the selected industries (infrastructure) and collects a large number of potential objects that can be recreated. Obviously, it is impossible to fit all of them within one project, so the most popular and suitable ones are selected from the huge list, while the rest are sent to the "idea storage", as they may be useful in the future.

At this stage, we look for experts: colleagues whose work is related to the industry, or external experts. When we have approved the list of objects and received expert opinions, we form and transfer the task of project development to the design studio. The expertise obtained helps us to prepare a competent and detailed technical specification.

Colleagues analyze our task, conduct their own research of industries and infrastructures, objects, technical and business processes. As a result, they also come up with proposals for the placement of certain objects inherent in the selected field that were not included in our sample. After that, the list of objects is re-approved.

Then the designers begin to place and draw the objects of the future layout. Depending on the complexity, this is possible either immediately in 3D or in 2D. At this stage, we make every effort to achieve the authenticity of the future layout and the processes on it :)

Then comes the longest part of the development. It takes place in an iterative format: designers provide their vision, the team that works on the layout, and experts leave their comments, according to which the model is changed and the process is repeated. On average, the design model goes through about 20 iterations during the development process. The process takes about two to three months.

At one point, the layout takes on a relatively stable form, and there are fewer edits. It is then that we begin to add details that make it come alive. We plan what and how will light up, move, where the screens, smoke, etc. will be, in other words, we plan a list of kinematic effects. This is not done randomly, but with reference to the processes we want to display. Dynamic objects are pre-planned to have several states: normal, pre-emergency, and emergency (there may be several of these if the object is involved in different processes), as well as intermediate states. Industry experts are also involved in this, advising us on the processes and reactions of the equipment to certain interventions.

The result of the design development is not only the appearance of the layout but also fully described technical and business processes, a table of future effects with a description of how they are proposed to be implemented and what states they should have. This information will later be needed by the layout workshop for production and the design team to create "bundles" of effects within the framework of the cyber battle.

At the final stage, a workshop is involved in the manufacture of the layout itself. We need to make sure that there is a technical possibility to implement the kinematic effects as we have conceived, and if this is not possible, we look for the best way to bring the ideas to life. For example, we needed to make an ore conveyor for the "Metal" layout - we did this using a screen.

When the design is developed and approved by the team and the layout workshop, it goes into production.

The main purpose of the layouts is to demonstrate the consequences of white hacker attacks on infrastructure objects. Its executive mechanisms are integrated with the industrial and corporate systems of the cyber range, which are the targets of the attacks. As in real life, such attacks lead to certain consequences, which we have depicted on the layouts. For example, when a hydroelectric power plant (HPP) or a thermal power plant (TPP) is stopped, consumers are partially disconnected (for example, lighting in residential complexes goes out), and when all power supply facilities are turned off, a blackout occurs.

Each layout presents more than 50 effects that can work both separately and forming "bundles" with attacks. One effect can be involved in several "bundles", which allows for different combinations of attack consequences.

For example, in the energy layout, we have HPP turbines. Normally, they rotate, but in the event of an accident, they stop. This happens if white hackers implement two critical events: "Stopping the operation of the hydroelectric unit at the HPP" and "Disabling the switch of the HPP technological network". In addition to the turbines, there will be other signs: the screen in the control room will stop showing technical indicators, a red beacon will light up at the top of the HPP, and the servers will be highlighted in the same color. However, in the event of the critical event "Data substitution on the operator's screen of the HPP", only the beacon, screen, and servers will be activated, while the turbines will continue to rotate.

Where do the bricks for houses and seedlings for trees in the layout come from

As expected, design is followed by production. At this stage, the 3D model is transferred to specialized software, from which samples for 3D printing, milling, etc. will be used. All this takes about a month in the background, with the workshop sometimes consulting with designers or the layout team.

Two processes occur in parallel: the purchase of equipment for the implementation of kinematic effects (motors, screens, LED strips, etc.) and the production of specially designed controllers.

We purchase equipment from all over the world. And although this procedure seems simple, in fact it is quite complicated: if you make a mistake in choosing or buy not enough spare copies, there is a high probability of not delivering the layout on time or making it with incomplete functionality, since it is often not possible to quickly purchase the necessary components.

Controllers are devices that were specifically designed for our layout in accordance with the requirements for the implementation of its functions. In other words, there is no "out of the box" device for the intended effects that will meet all the requirements. That is why a number of devices have been developed that allow us to customize the effects. These controllers control PWM devices (power control process by pulsed switching on and off of the energy consumer), stepper motors, SPI tapes. There can be several dozen such devices in one layout.

A story about how a layout is created in the engineering art workshop «Architection», look under the spoiler.

Workshop Story

We start the production of the model by receiving the technical specification (as obvious as it may sound). The customer sends us a 3D model and a set of renders with a description of the color scheme, as well as a technical specification for the development of controllers for stepper motors, PWM devices, SPI strips, and screens.

The most important thing in the technical specification is the development of scenarios for the operation of the model's kinematic effects with reference to critical events.

This stage is carried out in close cooperation with the customer (art studio) and production.

From this, we get a specification for:

1. Model control controllers.

2. Multimedia surfaces.

3. Lighting elements.

4. Kinetic elements.

This is important because the scenario development determines all further actions of the design bureau and production.

When we have thoroughly worked out the technical specification, the design engineer comes into play — the main person on the project 😎 His task is to design the model in such a way that all elements can be manufactured using available technological processes from understandable materials. He also solves the issue of further operation, maintenance, and transportation of the model.

The design engineer completely redraws the 3D model in CAD software: no polygons — only solid bodies. He distributes which elements will be printed on 3D printers, by what method (for example, FDM or photopolymer printing), what will be milled, what needs turning, where and how motors or screens will be installed, where each diode is located and how to route the cable to it.

After developing the engineering (technical) model, the preparation of production files and drawings begins.

The main tasks of another production engineer are to maximize the innovation pace and minimize the cost of products while meeting the necessary quality requirements. All this is done within the timeframe set by the manager.

In addition, we decompose the models into elements as follows: part – subassembly – assembly. The production shops start preparing the parts: first, it is 3D printing and CNC production. From there, the parts go to the fine arts shop (as we call our art shop), where our fairies stylize all the elements of the model according to the technical specification: they work out the texture of building facades, the texture of sand or water surface, paint the elements of the model according to the color scheme, and breathe life into the gray parts.

Then the electro-modeling shop comes into play — this is a team of people who deal with a wide range of tasks, from gluing and fitting elements and parts to each other, to soldering LED strips, controllers, laying wires, and installing kinematic elements. They assemble subassemblies and assemblies from parts, turning them into separate segments of the model.

After the assemblies are ready, the guys install the finished segments on the so-called cubasota and route the cable routes from each individual segment or element to the model control panel.

Then the model is connected to the control panel, and commissioning work begins.

In parallel with all this, there is a process without which it would be impossible to control any diode on the model, the scenarios would not work, and the kinematic elements would remain motionless — this is "Software development for controllers for controlling light, collector and stepper motors".

What is so special about these controllers?

1. Their work is based on the industrial Modbus protocol, which allows full control of all model parameters.

   This protocol is used in various factories to control industrial equipment. It allows full control of all parameters.

2. In addition, the ability to configure controllers via Wi-Fi is implemented, which greatly simplifies all commissioning work.

P.S. None of this could have happened without the sensitive guidance of our management! Their task is to minimize delays at key points of the project using all necessary labor resources, as well as to prevent possible risks.

Thanks to this person, we received, developed, and delivered everything on time 😊

I would like to highlight our cube cells separately — the cases in which the models are installed. In short, this is a custom device that was developed specifically for us, it performs several functions. After the model is mounted in the cube cell, all the logical part responsible for the functioning of all effects is installed inside. Thanks to the built-in drive, the model can be lowered inside the cube for transportation or raised up for maintenance and installation of electronics inside.

At events, this case serves as a beautiful stand, and PLCs are installed in its niches, which are an integral part of the attacked infrastructure, and touch panels (monitors) displaying SCADA mnemonic diagrams corresponding to these PLCs are installed above each such niche.

When the visual part of the model is ready, it is mounted on the base plate, and the electronics engineers come into play: it is necessary to install all the control modules on the mounting panel (controllers, single-board computers, power supplies, switches, etc.), connect all the actuators that were mounted on the model to them, and organize cable management.

Since there are a lot of actuators, this is a delicate and painstaking job: the slightest mistake can lead to a malfunction in the logic of the effects. For example, due to the density of the installation, it is necessary to shield each contact to avoid interference.

One, two, three! Christmas tree, light up!

Our model is a complex software and hardware system, but the product that we receive from the model workshop, although functional, will blink like a Christmas tree and make strange buzzing noises if you just plug it into the socket. In order for the model to become a full-fledged reflection of any infrastructure, the most important thing remains — to commission it.

The logic of our layout is set by the "Core" program. This software is specially designed to control the layout and allows you to control the layout effects in automatic, semi-automatic, and manual modes (this is exactly about the aforementioned "bundles" of effects developed by the project team). Scenarios are formed from them, which are launched from the "Core". It gives a command to the layout's control PC, which distributes commands to the corresponding controllers.

This is a very simplified description, since each controller and microcomputer needs to be flashed, the corresponding video sequence or effect needs to be "poured" into the screen and tape controllers (the process of creating effects for SPI tapes is an art, but in short, effects are developed for each diode separately, and there are 144 such diodes per meter of tape), all controllers need to be registered in the control PC, and many more manipulations and settings...

Epilogue

Sometimes something changes or is added at the last moment: while the electronics engineers are crossing wires under the layout, the model makers are gluing houses on stepladders, and the artists are painting boats and planting trees. And all this a couple of days before the Standoff!

But, looking at the layout's work during the show, I can say that everyone who participated in its creation did a great job (but didn't sleep very well) 😊

Should we release the second part with a story about how the layout and the online training ground interact with each other? Leave your comments!