DIGITAL TWINS IN CONTROL REALTIME

Transcription

1 ISG Industrielle Steuerungstechnik GmbH STEP, Gropiusplatz 10 D Stuttgart Phone: Fax: DIGITAL TWINS IN CONTROL REALTIME Simulation-based engineering for mechatronic systems

2 SIMULATION-BASED ENGINEERING FOR MECHATRONIC SYSTEMS Digital twins as basis for Industrie 4.0 The advantages of using digital twins throughout the entire life cycle become increasingly obvious: The virtual system image provides optimized machine design, efficient commissioning, short changeover times and a failure-free operation. The benefits of this technology can already be measured in numerous companies. The development of digital twins in the field of automation requires platforms that are able to implement virtual systems in control realtime and close to reality. Thanks to these platforms, concepts are validated at a very early stage and the machine controls can already be extensively tested within the virtual environment. Especially the bringing forward of the commissioning by using virtual components reduces the danger of disruption and failures that would be a lot more extensive to eliminate during real commissioning. Furthermore, when changing the production for new products, the changeover and downtimes of the real system can be reduced significantly. Last but not least, digital twins are used for remote maintenance, optimization of production parameters or training purposes. Digital twins with intelligent components A digital twin s set-up is made of intelligent components and thus comes up in detail to the set-up of the real system. More and more, (e.g. drive) producers deliver their real component accompanied by its digital twin: Interfaces, parameters and essential behaviour characteristics reproduce the real component at a 100%. Saved in libraries, these components are arbitrarily replaceable and reusable: For optimizing existing or modelling new systems. Testing also in an automated way How do different parameters of a component influence the machine? How solidly works a plant when an error occurs? What is there to be done when integrating a new robot into the existing plant? By which factor can the production velocity be increased without quality loss? By using real process and production data, reproducible module, integration and system tests can be effected at any time right up to factory simulations. Furthermore, the test automation tool ISG-dirigent enables users to do so in an automated way and integrable into the requirement management. Digital twins in control realtime ISG-virtuos enables test, commissioning and optimization of automation systems under consideration of real controls (CNC, MC, PLC, RC) including the communication via industrial fieldbuses in deterministic control realtime (1ms). Only then, the entire system s behaviour, i.e. the interplay of control and digital twin is taken into consideration in total analogy to the real system in the sense of a system test. As such, after transfer onto the real system the topic safety is truly safe. You have questions or special requirements? Do not hesitate to contact us. Fig. 1 ISG-virtuos simulation environment (here: Beckhoff control CX2040 via EtherCAT)

3 THE DIGITAL TWIN IN ACTION Client Requirements System engineering Processes Functions Disturbance settings Software engineering/commissioning Service Production monitoring and service Also after production start, the customer uses the virtual system: New processing sequences and production processes can be tested and optimized without disturbing the running production. Performance difficulties or failure situations are tested on the simulation system and rectified via remote maintenance or personnel on site. Existing digital twins are modified or upgraded by substituting or optimizing the digital components. Respective tests are effected for function and quality backup. Trainings can be held on the real control connected to the digital twin. Failure situations are provocated on purpose in order to train their safe rectification. Mechanics Virtual production plant/machine Electrical engineering Supply/ Mounting Real production plant/ machine Concept and development Product and performance optimization Fig. 2 Stages of simulation-based engineering Delivery Ramp-up FAT Concept/development, product/performance optimization, commissioning Service Commissioning By using original, imported engineering data (CAD data, master and electric configuration) the requirements of all departments involved are from the very beginning developed, tested and optimized on the virtual system. Either online with the real control connected via fieldbus or offline with virtual controls. Within the scope of virtual commissioning, the digital twin is taken into operation and can be accepted in form of a virtual Factory Acceptance Test (FAT). Already at this very stage, the compliance with the requirements is secured. Automation software errors have been detected, identified and corrected. As such, the real system is ready to be used and delivered. Fig. 3 Use throughout the entire life cycle Production monitoring

4 Digital twins for: Machine tools and machining centers Assembly facilities and automation cells Conveying systems and material flow Features Hardware-in-the-Loop-Simulation (1ms) Consistent engineering platform Vast module libraries Module-oriented modelling Mixed operation real/virtual components 3D visualization Numerous testing possibilities Software Development Kit (SDK C++) Realization and test of Axis kinematics Automation scenarios Processing scenarios including removal Material flow scenarios Failure scenarios including collision control Optimization of Cycle time Acceptance criteria Your advantages Maximum reduction of production ramp-up Ready to use already during concept phase and for customer acquisition Alternatives economically revisable Available 24/7 for training and optimizations Complex topics clearly presentable Risk-free know-how buildup in control, simulation and fieldbus technology

5 Numerous testing possibilities Module, integration and system tests both manually or automatized Failure scenario simulation on the basis of service data (component failure ) Test panels of controls such as displays, buttons, switches etc. Tracking/Recording of relevant signals and process factors Automated tests (ISG-dirigent) C omposition of test plans made of reusable and changeable test cases Reproducible results including protocols Support throughout the entire development and life cycle ISG-virtuos at Homag Group AG Mixed operation real/ virtual components Commissioning of real controls incl. fieldbus on virtual components Scalable test scenarios by using real and virtual components Gradual transfer of virtual components into real components Combination of Hardware-, Software- and Model-in-the-Loop simulations Integration of offline programming systems Vast module libraries Standard libraries (control systems, drives, fluid, logic, material flow, robots, tool handling, tool measuring etc.) with numerous function modules E.g. physical material flow Realtime capable physics engine Consideration of physical features (gravitation, friction etc.) Processing simulation (removal, pick-and-place, decollating, isolating, gouging etc.) Conveyor-based and guided transportation systems as well as handling, sensors, storage techniques E.g. Robot library (ABB, Fanuc, KUKA, Stäubli etc.) In-process measuring devices Customer-individual components integrable into module library Hardware-in-the-LoopSimulation (1ms) Direct connection of CNC, MC, PLC, RC via fieldbuses no gateway needed Use of original addressing and timing without adaption of control software Time-deterministic response time in control realtime/fieldbus cycle (1ms) Repeatable results enable Factory Acceptance Test (FAT) Simultaneous use of various fieldbuses including safety Automatic control connection of I/O-Master configurations for Profibus/Profinet and EtherCAT Consistent engineering platform Connection of various real controls (via industrial real fieldbuses) and projection/programming tools (via OPC, TCP/IP) C ontrols (e.g. Beckhoff, Bosch, Fanuc, Heidenhain, NUM, Rockwell, Siemens) Fieldbuses (e.g. CANopen, EtherCAT, Ethernet IP, PROFIBUS, PROFINET) O ffline programming systems (e.g. KUKA office lite, FANUC Roboguide, ABB RobotStudio, EKS RobSim) Scalable platform of component simulation right up to factory simulation as system test including Hardware-in-the-Loop/system test Development of custom-made, executable simulation modules with SDK C++ Co-simulation with specialized simulation systems via FMU (Functional Mock-up Interface) Module-oriented modelling Re-usable virtual components and modules Modelling of plant behaviour with parameterizable library modules Customer-specific modules set-up with SDK C++ Virtual components for intelligent fieldbus participants (drives, RFID systems, camera and measuring systems etc.) Correct behaviour of virtual components on fieldbus regarding interfaces, operation modes and parameters for the set-up of digital twins Usable for operation on real control (via fieldbus), for concept and projection (via OPC UA etc.) and intelligent services (via cloud services) 3D visualization Original CAD data import (e.g. CATIA, Inventor, ProEngineer, NX, SolidWorks, Solid Edge, Parasolid, STEP, IGES, JT, VAD-FS, ASIC, VRML) 3D visualization of modelled scenes in configurable perspectives Overlap of material flow elements with original plant 3D CAD data (layer) Dynamic display of process-relevant information for elements and material Operation with VR/AR lenses SDK Software Development Kit (SDK C++) Open automation platform for customized modules in C++ Development Kit for the quick development of critical realtime applications Usable for component providers for the set-up of virtual components considering the protection of knowhow Seamless integration into the ISG-virtuos runtime environment Quick skill adaptation training with development manual Access to all process factors (read/ write) ISG-virtuos at Homag Group AG

6 REFERENCES SOME ISG-VIRTUOS CUSTOMERS Harald Preiml, Managing board, HEITEC AG The only answer to long changeover times is a production plant technology that can be established in short time and that can easily handle variant diversity and small lot sizes. At HEITEC we rely on the virtual machine and commissioning with the simulation system ISG-virtuos which has it both: production plant and machine simulation as well as 3D visualization in realtime. Thomas Kirn, Senior Manager Electrical Engineering Software, Eisenmann Anlagenbau GmbH & Co. KG As an important part of E-PASS (Eisenmann PLC Application Software Standard), our internal engineering process for plc software, we use ISG-virtuos for virtual commissioning in order to test our system software. We are thus able to very quickly provide high standard client solutions. Ludwig Albrecht, Basic R&D, HOMAG Group AG We are positive about ISG-virtuos concept of simulation-based engineering. We are for example now able to already during the development phase set fixed data which we only need to adjust in the further process. Furthermore, thanks to the modular system, the always re-useable modules and the great variety of test functions, we were able to decisively simplify and accelerate many of our processes especially the commissioning of our production plants.

7 CONTACT Since 1987, ISG Industrielle Steuerungstechnik GmbH in Stuttgart, Germany develops innovative software solutions and technologies in the field of industrial control, drive and simulation technology. OUR CLIENTS REPORT ISG-virtuos is developed by a team of realtime simulation experts. This team supports companies in creating digital twins that accompany the machines and plants throughout their entire life cycle, especially during the development phase and virtual commissioning. 80% 20% REDUCED COMMISSIONING TIMES REDUCED PRODUCT DEVELOPMENT COSTS AND TIMES 30% REDUCED PROJECT COSTS 10% OPTIMIZED PRODUCTION PLANT PERFORMANCE We look forward to hearing from you! Dipl.-Ing. Ulrich Eger Division Manager ISG-virtuos, Authorized Representative ulrich.eger@isg-stuttgart.de Dr.-Ing. Christian Daniel Business Manager Simulation Technology, Consulting christian.daniel@isg-stuttgart.de