digital twin and real commissioning on virtual models · cycle test and program generation offline...

© ISG Industrielle Steuerungstechnik GmbH 2017 ISG-virtuos-Digitaler-Zwilling.pptx

Digital twin and Real commissioning on virtual models

The double for your stars Simulation-based engineering and virtual commissioning in control realtime (1ms)


Digital twin – Commissioning on virtual models

2

Virtual commissioning and digital twin

Test automation with digital twins

„Best practice“ applications

Physics-based material flow in control realtime


Expertise – control technology and virtual commissioning

3

ISG Industrielle Steuerungstechnik GmbH

CEO Dr.-Ing. Dieter Scheifele

Field of business ISG-kernel (since 1987)

Control software CNC, RC, Motion Control

Clients Control, machine and plant manufacturers

Field of business ISG-virtuos (since 2005)

Simulation software Virtual commissioning (VIBN) as

Hardware-in-the-Loop in realtime (1ms)

Digital twins

Clients Machine and plant manufacturers

Integrators / Plant users

~ 10.000 Machines of different technologies / per year


ISG-kernel – CNC, RC and Motion for complex kinematics

4

Copyright WAFIOS AG 2016

© ISG Industrielle Steuerungstechnik GmbH 2017 ISG-virtuos-Digitaler-Zwilling.pptx 5

Virtual commissioning and digital twin


Digital twin – Virtual commissioning (VIBN)

6

Aim / Expectations VIBN

Validation of requirement fulfillment (quality / performance, FAT) and

cognition, identification and error rectification within the automation software

Validation and optimization of control and norm strategies

already during concept and/or engineering phase

Significant reduction of real commissioning

by anticipation of (a preferably big) part of the real commissioning

Minimization of down times during service, maintenance and restructuring of existing plants

by safeguarding the solution

Test of critical (also risky) operational states of the plant

due to misuse, component defects or damages


Digital twin – Simulation-based engineering

7

Objectives / Features

Conversion of inflexible,

sequential processes into agile

„systems engineering“

Software engineering including

commissioning

as leading process

Virtual plant / machine is

constantly available for

dimensioning testing and

optimizations

Failure situations are considered

from the very beginning

virtuelle Inbetriebnahme kann

ohne Einschränkungen auf die

reale Anlage / Maschine

übertragen werden

Beschaffung

Montage Mechanik

Auslieferung

Produktionsstart

FAT

Software/Inbetriebnahme

„es fehlt nur noch die SW“ Elektrik

reale Anlage

/ Maschine

Team „Technik“

Ideen

Layout

Baugruppen

Kunde

Anforderungen

Bruch im Software-

Engineering

Sequentieller Engineeringprozess

(vorwiegender Status quo)

Systems Engineering

Processes

Functions

Failure scenarios

Mechanics

Electrical design Provision

Mounting

Delivery

Ramp-up

FAT

Real plant

/ machine

Virtual plant / machine

Software engineering incl. commissioning

Clients

Requirements

Service

Agile engineering


Real automation system

Digital twin – Simulation models

8

Model-in-the-Loop

(MIL)

Software-in-the-Loop

(SIL)

Projection

Designing of system

layouts

Generic and hardware-

independent description of

control task

prototypical control code

Cycle test and program

generation

Offline programming

Emulated, i.e. virtualized

control

Generation of control

code as serial code

(e.g. according to

IEC61131-3)

Standard communiation mechanisms

Shared Memory

OPC UA

TCP/IP …

Real controls with real control

code

real HMI including all user

interactions

Real fieldbus systems

E.g. Profibus, Profinet, EtherCAT

Including safety

No „Gateways“

Virtual system / machine of virtual components

Tool kit system for behaviour models and 3D visualization

Process simulation / Material flow

Removal simulation / Collision detection

Virtual components

Behaviour models and 3D visualization strictly separated

Realtime deterministic behaviour of virtual components (1ms)

Connectable 1:1 as fieldbus participants (same addressing, same behaviour including safety)

System / Process

HMI

Controls

Communication

Profinet

EtherCAT

…

Components

Sensors / Actors

Hardware-in-the-Loop

(HIL)


Digital twin – Virtual commissioning (as of 2017)

Use of simulation tools Survey

What are simulation tools in your company are used for?


Digital twin – Virtual commissioning (Trend / Requirement 2017+)

Development potential Future need for simulation tasks

Share of companies with a growing or strongly growing need for simulation tasks


Digital twin – Hardware-in-the-loop system

11

Features

Construction of virtual machine

/ plant with virtual

components

Behaviour of virtual

components regarding

interfaces, parameters and

operation modes just like real

components

Virtual commissioning with

reproducible responsive times

in control realtime (1ms)

including SAFETY

Real controls

Beckhoff

Bosch

B&R

Fanuc

Heidenhain

Rockwell

Siemens

…

Real fieldbusses

CANopen

EtherCAT

Ethernet IP

Focas

Powerlink

Profibus

Profinet

OPC UA …

Digital twin


Digital twin – Virtual components for automation

12

Fieldbus

Real control Real fieldbus participants Real components with

realtime behaviour

Real machine / plant (Components, overall behaviour material flow)

Virtual machine / plant (Components, overall behaviour, material flow)

Configuration

Configuration

Virtual components

with realtime behaviour

Real fieldbus participant

1:1 Reproduction of components

„virtual

clamps“

Emulation

1:1 (I/O, Safety …)


Digital twin – Reuseable virtual components

13

HILS (fieldbus)

Real control Virtual component Fielbus participant

Fieldbus

(Multislave)

Virtual plant

Virtual plant

IT network

connection

OPC UA

TPC/IP

… Conception,

projection …

Cloud

services

WEB-

Services

Intelligent services

Virtual components /

Technology objects


Digital twin – Agile engineering processes

14

3D CAD system

(mech. construction)

Mechatronical components

(mech. / electrical construction )

Control technology

(software, commissioning)

3D visualization

(motion, processes)

Behaviour

(logics, kinematics, material flow …)

Test, optimization, training

(signals, fieldbus participants, drives …)

Rea

l c

om

po

nen

ts

Vir

tual

co

mp

on

en

ts


Digital twins – Modelling of reuseable components

15

Features

Company-owned library as

KnowHow setup and protection

Validated part- / sub models

Efficient engineering by re-use

Process optimization by

automated model generation Real components

Configuration 1

Solution / KnowHow library Configuration n

Virtual components Model library


Digital twin – On the example hydraulics / pneumatics

16

Components LIB


Digital twin – 3D visualization CAD systems

17

3D-Visualisierung 3D CAD system

Direct import of the following formats

CATIA Inventor Pro Engineer VRML

NX SolidWorks Solid Edge

Parasolid STEP IGES

JT VAD-FS ASIC

3D components library


Digital twin – Connection of controls

18

Ex. Siemens – TIA Portal / S7-Manager

Import

GSD

TIA

Po

rtal

I/O-Master configuration

TIA Konverter

Openness V14

ISG

-vir

tuo

s

I/O-Wizard

I/O-Multi-Slave

Profinet

Profibus

1. Transfer of master configuration and device master data GSD(ML)

2. Generation of ISG-virtuos realtime solution

Generation of realtime project with emulated clamps (I/O multislave as fieldbus participant)

Selection of the I/Os to be simulated (mixed operation possible)

3. Connection of real control via the real fieldbusses

Original addressing and same fieldbus cycle time (e.g. 1ms)

All virtual clamps are realized as fieldbus participants (including I/O-Safety)


Digital twin – Complex, linked production systems

19

Integrated test / simulation of complex

automation solutions

Simulation system easily extensible via

fieldbus mechanisms

Combination of Hardware-in-the-Loop

simulation with real automation systems

Superior 3D visualization of entire plant

„Factory Acceptance Tests“ for complete

production systems

Fertigungslinie

Fertigungszelle

Transporteinrichtung

WZM

SPS SPS CNC

Bussystem

Leitrechner

SPS SPS

CNC

Bussystem

Leitrechner

Complex HIL plant simulation by

segmentation and realtime coupling

Feldbuskopplung

Feldbus Feldbus Feldbus


Digital twin – open, extensible simulation platform

20

Projection and programming tools

Engineering tools Virtual commissioning

Real fieldbusses

reale Steuerungen

SDK C++

Realtime solver

4155

577.04

4512120

4155

44498.045

55185.121

4155

577.04

4512120

)ln(

)(

,,

,,

,,,,

einWausÖl

ausWeinÖl

einWausÖlausWeinÖl

m

3D visualization Test panels

Modelling

Module

library

Integration platform

KUKA office lite

FANUC Roboguide

ABB RobotStudio

EKS RobSim

…

Offline programming systems Projection and layout

ISG CNC.sim

IFF Vincent

CENIT FastSuite

…

Standard interfaces (UDP, OPC, TCP/IP)

OPC-UA Client

TCP/IP-Treiber

SYS / DLLs

…

Real controls


Digital twin – Software Development Kit (SDK C++)

21

Benefits

Realization for own modules also

for realtime applications in C++

Open automation platform

Executable in TwinCAT 3.1

Fast familiarization with developer

manual


„Best practice“ applications


„Best practice“ – Users and partners

23


„Best practice“ – Plant and machine engineering, HEITEC AG

24

Additional value

Short commissioning times and

optimum software quality

Test of extreme situations without

any risks

Re-use of mechatronic modules

Generation of improved approval

criteria

Optimization of service and

maintenance

Training and qualification of staff

By courtesy of HEITEC AG


„Best practice“ – Digital twin / factory simulation, HOMAG

25

By courtesy of HOMAG Group


„Best practice“ – Packaging, KOCH Pac-Systeme

26

By courtesy of KOCH Pack-Systeme GmbH


„Best practice“ – Engineering process, EISENMANN SA

27

By courtesy of EISENMANN SA

E-Pass, EISENMANN SA


„Best practice“ – Training concept, ZF Friedrichhafen AG

28

Aim

Staff training and further

qualification of Schulung on the

digital twin

Optimization of service and

maintenance

Reference for assembly cell

providers

mit freundlicher Freigabe der ZF Friedrichshafen AG, Schweinfurt


„Best practice“ – Training system with digital twin

29

Control hardware

Simulation platform Windows

KUKA: OfficeLite (VMWare)

S7-300

Echtzeit (TC)

Sim-PLC

Box 10: DPDP Roboter

Achs

werte

Box 60/70 CUBE EAs

Box 12, 13, 14:

DPDP Maschinen

Box 16: Auslaufband

Box 20 BIS-C: RFID

EtherCAT Master

Euchner:

Electronic-Key

EK

1100

KPC

TCP/IP

Solver Box 03: Jokab Safety

Wago: Bedientafel

RS

232

32 E

32 A

RS

232

32 A

32 E

Switch

M V

TCP/IP

HMI: WinCC

Baustein: SPC

Baustein: WM

Baustein: Nieten

Kommuni-

kation

KRC – S7

Profinet

Profibus

direkte E/A

VxWorks

KRC

ProConOS

Windows

HoloLens-Manager

direkte E/A

WLAN

Mobile

end devices

Control panel /

devices


KraussMaffei

Machine and plant engineerin gin the

field of injection molding machines

Requirements

Detailed test of various client

configurations

Electric and hydraulic machine

clamping forces up to 54.000 kN

Results

Process control via control of virtual

models in control realtime (1ms)

Automated configuration of control and

simulation model according to sales

order

Simulation (logics, kinematics,

dynamics (hydraulics)) of every

delivered machine

„Best practice“ – Injection molding machines, KraussMaffei


Physics-based material flow in control realtime


Material flow – Client requirements

32

User requirements towards material flow simulation

Complete commissioning as system test up to FAT (factory acceptance test) in control

realtime (1ms) including Safety

Cycle time optimization considering the real controls (HILS)

Set-up of a real digital twin composed of virtual modules / components, which show the

exact same interfaces, parameters (static and dynamic) and time behaviour as the real

modules / components

Easy amplification and/or adaption of the virtual twin as configuration process when

changing the real system

Material flow including machining simulation (removal simulation, cutting, joining …)


Material flow – physics-based material flow in control realtime

33

Features

Realtime-able physics engine

tailored to the requirements of plant

and machine engineering

Motion processes result from

impulses during collision of bodies

(material flow elements and material)

Physical features such as e.g.

gravitation and friction are taken into

consideration

Robotics and handling systems

included

Material features dynamically

changeable according to handling

processes Time-deterministic surveys taken from:

Simon Hoher, „Ein gekoppeltes Materialflussmodell zur durchgängigen Entwicklungsunterstützung von

Materialflusssteuerungen“, Universität Stuttgart, Fraunhofer IPA, Fraunhofer Verlag 2017


Material flow –Module library

34

Flawless integration in ISG-virtuos

Library with standard modules included

Simple modelling thanks to consistent architecture, process and

interface

Ex post amplification of existing models

Easy connection to control signals

Fully automatic visualization of the modelled scene

Material flow elements

Path-guided materials handling

SKID (conveyor-based) materials handling

Handling

Sensors

Storing technology


Material flow –module-oriented modelling

35

Behaviour of material flow elements

Writing devices dictate behaviour of material flow

elements and material

Reading devices identify characteristics of the

elements

Writing and reading devices are connected to the

material flow elements via consistent interfaces

The behaviour can be changed afterwards by adding

further devices

Benefit

Intelligibility thanks to standardized modules with in-

and outputs

Clear arrangement, given that only relevant

characteristics are modelled

Ex post amplifications of existing models

Device

Writing devices

Device

Reading devices

Element

Material flow


Material flow –“Elements“ from module libraries

36

Transportation Handling Sensing Material Pools & Storing


Material flow – graphical 3D-modelling

37

Features

Automatic display of the modelled

material flow elements in 3D

Positioning and parameterization

of material flow elements within the

layout

Overlay with the plant‘s original 3D

CAD data (layer)

Dynamic display of process-

relevant information for elements

and material

Easy engineering by coupling of

behaviour model and graphical

representation


Material flow – Simulation models made of modules

38

Additional value

Easy understanding of the model

behaviour on the basis of the block

diagram (no programming)

Automatic model generation thanks

to simple configuration process

3D visualization available „on the

click of a button“

Overlay of CAD and material flow

element geometries is possible

Hoch-

regal-

lager

Umwerfer

Regal-

bedien-

gerät

Eck-

umsetzer

Licht-

schranke

Linear-

förderer


Material flow – System test (handling / processing)

39

KUKA CNC - HMI

ISG-virtuos – Test scenario

ISG-virtuos – 3D visualization and removal simulation

ISG-virtuos – plant model


Material flow – Removal simulation and collision detection

40

Removal simulation

Precise, foto-realistic display

Working progress in realtime

Collision detection

Definition of body pairs

Display and signalling of collisions


Co-Simulation – ISG-virtuos as integration platform for the VIBN

41

Windows-based

material flow

simulation

(AgX Dynamics)

Time-deterministic

realtime material flow

(MFphys)

Cooperations

Research

LIB

z.B. Physic Engine

Bausteinbibliothek

Konfiguration /

Parametrierung

Integration of

simulation libraries

Inclusion of external,

self-contained models E

ing

än

ge

𝑢

Au

sg

än

ge

𝑦

Parameter 𝑝

FMU

Functional Mockup Unit

MapleSim

Matlab


Test automation with digital twins


Test automation – Development

43

Test on the real system

▼ Can only be effected after completion of the system

▼ Prolongs the system‘s delivery time

▼ Risk of damages on the system

▼ Fault-prone due to the human factor

Test with real controls on virtual systems (HILS)

Can be effected before delivery of the system

Vast and risk-less tests also of failure situations

▼ High expenditure when effecting vast test scenarios

▼ Fault-prone due to the human factor

Automated test with real controls on virtual systems

Increased software quality thanks to increased test coverage

Reliable results thanks to excluding the human factor

Reproducible test results including protocolling

Integrable into requirements management

pas

t to

day

new

VIBN

CAST


Test automation – Model-based test scenarios

44

Additional value

Test automation on the basis of digital twins

supports the entire product development cycle

including the commissioning

Components-, integrations- and system tests are

effected according to comparable test cases and

plans and lead to significant cost savings

Model-based test plans are generated easily and

without programming knowledge and are easily

understandable also for training purposes

Flexible test processes support dynamic and

parallel processes and consider process specific

preconditions


Test automation – Graphical test preparation

45

Advantages

Fast and easy preparation of

actions with graphic modules

also without programming

knowledge

Modules are being linked via

drag&drop to more complex

actions and/or test cases

Test cases can then be summed

up into test plans

Test can start straight away

Single action

Waiting for

condition

(Loop)

Connections

Verification

parameters

(dynamic)

Review on target

deployment

positive and/or

negative test

results


Test automation – Project structure

46

Features

The test automation system

enables reproducible tests thanks to

test plans including test protocolling

Test plans are created by combining

re-useable test cases / actions

Test plans can be administered for

repeated tests and analysis in one

test suite

Test scenarios can be recorded

Recorded actions can be changed

amplified and/or parameterized

Test plan

Test cases

Test

actions


Test automation – loggable test results

47

Features

The test result is transparently

shown in the test plan

Within the project structure, a

negatively finished test case is

marked and thus recognizeable at

once

For every negative test result, error

cause and the matching parameters

are displayed

The test result is protocolled in an

adjustable level of detail

Status for the entire

test plan

Positively finished test

cases

Test error including

error cause

Negatively finished test

case


Digital twin – Economic use

48

Virtual commissioning leads to :

We happily support you in implementing

simulation technology in your company.

By means of an introductory workshop,

we check the specific requirements for the

precise realization of your project at short

notice.

.

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