Plant Simulation as a Service

Transcription

1 Plant Simulation as a Service Higher quality and reduced costs for your products and processes Your benefits at a glance Shortening of commissioning times Avoidance of collisions without interference with real operation Reduction and avoidance of production standstills Improved software quality Minimisation of costs Possibilities for operator training Optimisation of the production processes/logistics Increased productivity

2 Plant Simulation Simulation services HIL simulation BoHleneck analysis Plant op+misa+on Throughput calcula+on Material flow calcula+on Material flow simulation Increase of produc+vity Virtual reality 2

3 So9ware op+misa+on Operator training Time op+misa+on Cost reduc+on HIL test enviroment Hydraulics simulation Hydraulics calcula+on Process analysis Energy balance Fault analysis Control Stereoscopy Spare parts Customer presenta+on 3D visualisa+on Collision analysis Energy flow simulation 3

4 Plant Simulation HIL simulation Virtual test environment for effective software development and commissioning Prototypes & new plants A smooth market launch of newly developed systems is now very simple thanks to modern virtual test environments. Parallel to the production of the first machine parts, the machine software undergoes exhaustive analysis and optimisation in the test field of the SMS group. The CAD data are thereby projected onto a screen and the movements and material flow can be observed in real-time. The real controller with the programmed automation software is linked to the simulation computer via the dedicated field bus interface following the Hardware- In-The-Loop (HIL) approach. The outputs from the PLC are read out and input into the simulation model. Depending on the signals, the model performs virtual actions, such as e.g. the switching of a solenoid valve, that can lead to a cylinder being extended. The movement is displayed in the 3D model and resulting signal changes, such as the tripping of a limit switch (here: cylinder is extended), are written back to the controller by the model (PLC inputs). The programmer is therefore able to operate and test the machine in real-time even before commissioning. Thanks to this innovative virtual commissioning approach, expensive collisions can be recognised and prevented in good time, and numerous problems and time-consuming work on the customer s site can be avoided. Programming errors can thus be detected and remedied much faster and more easily. 4

5 Highly complex production lines The virtual test environment allows even highly complex systems to be tested in combination. The communication between host computer, transport systems and machining centres and the respective programs can be analysed and developed further using the HIL approach. Benefits are gained when individual systems are already integrated into the production process and a production standstill has to be avoided. PLC software optimisation The final machine movements generally take place during commissioning in the customer s works. The goal of the programmer here is to avoid collisions and to fulfil the required function. Due to a lack of time and a shortage of the necessary tools, machine movements are seldom optimised. A simulation opens up a wide range of possibilities for optimisation here, particularly for the PLC software. Machine movements can then be designed so that extreme vibrations from the system are reduced. This protects the material and the expected service life is prolonged, and even an increase in material throughput can be achieved in this way, so that simple modifications to the software alone allow an increase in productivity. 5

6 Plant Simulation Virtual Commissioning Virtual commissioning of a tube welding line 6

7 Virtual commissioning offers a wide range of benefits that become particularly apparent in project management and the integrated time management. International teams often work together on a project, and the project manager is ultimately responsible for ensuring that commissioning is smooth and on schedule. In order to avoid the programmer turning up in the customer s works with software that is not yet finished, testing in advance as part of a virtual commissioning is absolutely essential. This approach is indispensable today, as the continuous increase in software complexity means that you can no longer see from the outside whether or not a program is complete and fault-free. Apart from the objectively measurable benefits, virtual commissioning naturally also offers a multitude of soft benefits. These include, for example, no risk of crashes, tests of new functions and operator training without interference with production and steeper ramp-up curves for the production line during commissioning, as setting parameters can be found faster and more easily. Engineerimg drawing of plant shown in the left picture 7

8 Plant Simulation Expansion and Optimisation of Existing Plants Virtual planning and implementation of your ideas Not only new developments present a company with major challenges; the revamping, expansion or optimisation of existing machines and plants is becoming more and more commonplace. Plant simulation is a very powerful tool especially here. No-one wants the production processes standing still for longer than absolutely necessary, or wants to worry about the machine no longer being productive after the revamping. A high-quality plant simulation allows these risks to be minimised in advance. Incorporation of original design data The integration of the 3D CAD data allows the whole production process to be analysed very precisely. As a result, design errors or collision risks can be recognised and eliminated in good time. Technical processes and safety functions can be observed in quasi-reality and improved, if necessary. Validation of the engineering data The technical engineering data, such as electrical circuit diagram, hydraulic circuit diagram, description of functions, etc. form the basis for the preparation of the simulation so that these are already examined very closely during the creation of the model. Incorrect relationships and errors within the data are immediately recognised and can be remedied in good time, thus saving further costs. 8

9 Virtual HMI The HIL test environment offers the possibility of linking real control desks to the simulation system. Functions and links between the control links can therefore be tested in advance. For organisational reasons, however, it is often not possible to make the control desks available for the virtual tests. The solution to this problem is virtual HMI. Thanks to the virtual simulation of the control desks it is possible to adopt the design and all the functions of the control desks. This ensures that the machine can be fully tested and realistic control of the machine is assured. Operator training and debugging using a digital twin Particularly in the virtual world, no-one has to be concerned that the machine could be damaged due to an operator error. This advantage is frequently used by customers to train their staff in advance before they are allowed to operate the real machine. The simulation enables special error scenarios to be called up at the press of a button in order to study important operating routines without risk. Training directly at the virtual machine is well received by the operators, as they can safely control the machine and test out all the functions. The operator quickly gets to know his machine using the virtual model and can thus be gradually prepared for his new duties. It is also possible to transfer special situations from the real production machine to the digital twin in order to virtually simulate and analyse fault scenarios that may be attributable to an error in the programming. The situation can therefore be analysed without stress and the pressure of time while production continues to run in parallel. Optimisation of a wire rod mill The benefits at a glance Remedying of faults in the engineering data in good time Error detection and remedying in the PLC software Testing and correction, if necessary, of the safety functions and technical processes Detection of design errors Operator training Avoidance of real collisions Reduction in commissioning time 9

10 Plant Simulation Process simulation Physics models in Matlab SIMULINK In addition to HIL real-time simulation, process simulation offers an enormous array of new perspectives for new developments, but also for problems occurring in existing machines and plants. Process simulations are therefore regularly used in the SMS group for the design of technological processes. MATLAB Simulink allows the engineers to calculate complex multi-dimensional processes. Particularly today, when energy-efficient machines and plants are becoming more and more important for our customers in order for them to remain competitive, process simulations help to simulate and illustrate the dynamics of a machine part, the resulting control behaviour, the forces involved or even the energy flows in a model. As a result, the whole behaviour of the machine, and in particular the interactions, can be investigated and optimised. Multi-dimensional physics simulation 10

11 Linking of HIL real-time simulation and physics simulation The Simulation department of the SMS group has gone one step further than the conventional applications of physics models. A method has been developed by means of which physics models can be integrated into a real-time simulation. This approach is unique and offers a large number of benefits. The programmer is thus able not only to initiate and observe individual movements of the machine, but can also draw on the calculation results for physical parameters calculated parallel to the real-time simulation. The programmer can then see, for example, the material deformation resulting from positions and speeds and can set his control parameters using the virtual model. Realistic machine behaviour using the game and physics engine A game engine (with integrated physics engine) is used to realistically image the material flow and to give the user of the simulation the feeling of standing in front of the real machine. This engine cyclically calculates simple physical effects, such as gravity and friction. This is a great benefit with very complex processes, such as a production facility the size of a football field. Frequently even minor phenomena are detected here, such as a blank rolling away or the collision between materials. The coupling of the game engine to the HIL simulation is an in-house development of the SMS group and not available in this form on the market. Coupling of physics engine and real-time simulation 11

12 Plant Simulation Virtual reality Interactive realistic perception The spare parts service of the future Interactive 3D model for spare part identification and ordering Which customer is not worried about a production standstill? If a component breaks or fails, fast help is crucial. Every minute of standstill results in high costs. The interactive and virtual spare parts service concept of the SMS group makes this fast help possible. The customer receives a virtual tool with which he can view his machine in a 3D model and have spare parts displayed individually. As a result, he is both well informed and can order spare parts directly from the manufacturer with just a few clicks, i.e. with minimum effort and loss of time. 12

13 Convincing customers of a product is always a great challenge particularly when the product is still in the development phase. Presenting the customer with something tangible here generally involves considerable expense and requires special techniques. More and more companies are now following new paths and taking advantage of the very impressive and varied possibilities offered by virtual reality. Here you enter an interactive virtual environment and gain a realistic impression of a product or a whole plant. This enables the customer to get a very quick but thorough overview so that he is able to discuss his wishes with the developers. Further benefits are the savings in cost and time achieved through the substitution of expensive and time-consuming production of prototypes or samples. The optimum communication with the customer from the outset helps to avoid errors in interpretation, and hence costs and delays in the later delivery and commissioning. Many companies also make use of this technique at international trade fairs to strengthen their competitiveness. 13

14 Plant Simulation Material flow simulation Planning, analysis, optimisation Material flow simulation is an analysis tool for examining logistics processes in a plant. Fields of application are performance measurement of a plant, but also the generation of optimisation findings. Individual events are thereby defined and then linked as in a network. Failure probabilities and tooling times can also be taken into consideration in the simulation. The simulation time can be freely selected so that an annual production can be calculated within a few minutes. Reports then allow pie charts to be generated for individual machine parts showing the loading as a percentage, making material flow simulation an optimum tool for analysing and optimising production lines. The simulation also serves as a successful basis for discussions, during which a suitable solution can be quickly found. According to VDI 3633, the cost/benefit ratio of a material flow simulation is 1:6. The costs are slightly higher during the planning phase, but are more than recouped later in the operational phase. Material flow simulation of a wheel rolling line 14

15 Boost productivity Many machine and plant owners are faced with the great challenge of operating their production facilities with the highest possible productivity. Just-in-time production, in particular, is difficult to manage. When quantities vary widely and different product types are produced in parallel on one line, plant operation becomes a real challenge. Thanks to its many years of experience in material flow simulation for industrial-scale plants, the Simulation department of the SMS group has found an effective way of precisely describing a plant mathematically in order to analyse the productivity. The findings are then assessed together with the customer in order to identify the most appropriate optimisation steps for him in the plant. SRP-R processing idle waiting for transporter 28.33% DRAW processing idle blocked waiting for transporter 43.32% 1 3 Waiting for discharge Machining PortalRobot 1 travel empty travel loaded offset travel empty offset travel loaded idle 36.49% PortalRobot 2 travel empty travel loaded offset travel empty offset travel loaded idle 42.54% Waiting for infeed

16 SMS group GmbH Ohlerkirchweg Mönchengladbach, Germany Phone: Fax: Internet: The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract. SE-354E Published on Circulation 500 Printed in Germany KD