b07_process simulate virtual commissioning

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved Siemens PLM Software Process Simulate Virtual Commissioning Shay Shomroni Director Industry Solutions Manufacturing Business Group [email protected]

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Page 1: b07_Process Simulate Virtual Commissioning

© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Process Simulate Virtual

Commissioning

Shay Shomroni

Director Industry Solutions

Manufacturing Business Group

[email protected]

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© 2011. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Shop-floor challenges

HMI synch

with tools

Throughput

reaction

Sensor

positioning

Tool

change

procedure

Electrical

device

signals

Safety

procedures

Handling

variants

Conveyor

optimization

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© 2011. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Virtual Commissioning

Environment for testing, simulation and debug of PLC programs, HMI

code, and automation scheme with a virtual model of a factory

Faster

• Shorter time to production

• Quicker change cycle

Better

• High quality PLC code

• Optimized performance

Less Expensive

• Cost of production stop

• Cost of prototype parts

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Story board

OEM XYZ Supplier 123

+

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Supplier Analyze: What is required?

Tooling

Clamps and Pose sensors address new variant

Robotics

OEM Standard program considers pedestal gun and new variant

Control

HMI test for clamps, safety procedures and E-Stop pass

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Primary Line Builder Challenge

Validate OEM changes faster and more accurately

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Tooling Tasks

Adaptation of Process, based on existing design

Define clamp functionality and specific behaviour

Mapping to PLC Signals and dynamic testing

Change the existing Process to multi variant

Correct Material Flow

Variant Detection

Mapping to PLC Signals and

dynamic testing

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Tool design Example

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

OEM instructions

OEM XYZ Supplier 123

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

The Use Case: Requirements

Traditional Work cell Simulation

Variants

Safety

Synchronization

Native Language

OEM Standards

Maintenance

Peripheral Resources

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Robotics engineers tasks

Manage changes after receiving a new path:

Variant Branching

Synchronize robots to PLC

OEM Standard Robot Code

Download programs and test

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Robotic Simulation

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Event-Based Simulation

Realistic cycle time

Conveyor control (physical, logics)

Material handling between stations

Load, steady state, variants and shutdown

scenarios

OP 3

OP 2

Time based

OP 1

OP 3

OP 2

Event-based

OP 1

A

NOT A

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Supplier Analyze: What is required?

Tooling

Clamps and Pose sensors address new variant

Robotics

OEM Standard program considers pedestal gun and new variant

Page 16: b07_Process Simulate Virtual Commissioning

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Control – virtual commissioning

Mechanical Electrical

Kinematics

Robot Programs

Mechanical Sequences

Layout

Clearances

Cycle Time

Inputs / Outputs

Logic

Interlocks

HMI

Diagnostics

Safety

Evaluate Mechanical and Automation System behavior

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Easily create a realistic shadow of a production

environment

Test & Debug PLC code

Long before the real system is build

Minimize impact on existing environment

Use real PLC H/W or emulated S/W

Start of

Production

Test earlier Don‘t disturb

production

Virtual Commissioning

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

VC Environment

Contr

ols

S

imula

tion

Process

Knowledge

OPC (Client & Server)

Signal

Mapping

Real Time

Signal

Exchange

PLC Code

Automation

Validation

Digital Process

Design

PLC HMI

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Virtual Commissioning Demo

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Life Cycle Processes (Current State)

Equipment Design

Controls Design

Workcell Simulation

Estimating Planning Design Construction

Installation Try-Out Program

Robots Debug

Process Planning & Documentation

Cost and Time

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Life Cycle Processes (Future State)

Equipment Design

Controls Design

Workcell Simulation (Enhanced)

Estimating Planning Design Construction

Installation Debug (Physical)

OLP

(Enhanced)

Debug

Process Planning & Documentation

Try-Out

Cost and Time

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

AMT Testemonial

https://sales.industrysoftware.automation.siemens.com/accesscount/24847/Virt

ual-Commissioning-Video-AMT-Testimonials-R7T4N3

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Benefits

Estimating Planning Design Construction

OEM

Tier 1

Primary LB

Tier 2

Eng Houses

Earlier start of production

Lower cost on changes

Major Risk reduction:

Mature processes

Right the first time

Standardization of processes and components

Collaborative and Efficient Engineering

Validation reduces risks on site

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

Process Simulate Take Aways

Highly functional & easy to use

Widely deployed by OEMs and LB

Natural upgrade of Robcad

Connected to TC backbone

Proven value and customer benefits

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© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

THANK YOU!