virtual manufacturing solutions - automate manufacturing process, which will meet the planning...
TRANSCRIPT
Virtual Manufacturing Solutions
Lee Van EverySenior Account Executive
CENIT North America
Industry 4.0 – The Next Revolution?
• What is Industry 4.0?
• Interoperability - Equipment, Human Communication through Sensor
Connections
• Information Transparency – Sensor Data allows Virtual response to real world
information, 3D Digital Components to behave as Real Components
• IoT – Internet of Things concept is the Core
• Digital “Smart” Factory – Agile Virtual Environment, Digital Twin
Advanced Manufacturing, Paradigm Shift?
Wikipedia
Industry 4.0 – Next Industrial Revolution
Digital Factory
Industry 4.0 - Components
• What elements comprise the next Industrial Revolution?
• Many of these components are in use today• 3D Mechanical Design & Planning• Autonomous Robots• Simulation• The Cloud• System Integration• Cyber-Security - Ultra important for Industry 4.0
• Internet of Things• Largely inter-networking between physical equipment
allowing the storage and exchange of data• 1982 Coke Machine! 1st example Wikipedia
3D Simulation Software: Key Component
• 3D Initial Concept – User Friendly, CAD components should mimic real world components (Conveyors, Controllers, Robot Arms)
• Validate Concept – Reach study, Virtual Teach Programs or CAD-To-Path Technology, Signalling
• 3D Simulation of Concept
• Generate True PLC / Robotic programs
3D Concept - Make Life Easier
• Fast Cell Layout – Drag & Drop
• Mechanical & Electrical Connections – Mimic shop floor
• Immediate Reach / Validation Study
• Simulation w/ all active components
• High End Rendering
3D CAD Components
• CAD Resources - Usability• Behave Correctly
• Intuitive
• Easy to Adjust (kinematics, velocity for cycle times)
• Smart Connections
• Cable Dressing
• Import CAD formats
• AML – Automation ML – reserve kinematics
• On/Off Signal Calls – simple parameter
Today’s Engineering Process
Simulation Based Engineering Process
3D Concept Validation
• Targets
Create simple robot motion programs, using the 3D simulation model to verify feasibility, reachability and cycle time
• Tool path teach
• Collision check
• Rough cycle time prediction
• Purpose
Define simulation layout and manufacturing process, which will meet the planning premises.
• Layout space
• Costs
• Production volume
3D Concept Validation – cont’d
• Internal standard motion planner
• Internal standard robot control
• OPC-UA – Open Platform Communication
• What is required to achieve targets?
• Reachability check
• Programming of positions
• Collision check
• Cycle time analysis
• How to achieve this?
Viewer
Kernel
OPC-UA
Solver
Logic
Mechanics
Dynynics
Material flow
Collision
Shares MemoryShares Memory
SimuCtrl.
SimuPLC Ctrl
Simulation Concept - Infrastructure
Fieldbus
Viewer
Kernel
Shares Memory
OPC-UA
Solver
Logic
Mechanics
Dynanics
Mat. Flow
Collision
Shares Memory
Shares Memory
External
OPC-UA
Resource & Layout Builder
Automation ML
Physical Behavior
I/O Signals
Adapter
KInematics
3D Geometry
Logic Behavior
real time External
Automation-ML
External virtual time
Simulation viewing
Behavior solving
Internal motion planningInternal logic
External motion planningExternal logic
Robot Offline Program Validation• TargetsCreation of robot programs, which will not require re-teaching on the shop floor
• collision free
• energy optimized
• cycle time optimized
• PurposeCreate robot programs, using the 3D simulation model to verify the quality of the toolpath and validate the programs
• tool path
• signal communication
Robot Offline Program Validation cont’d
Kernel Control specific robot behavior models
Connection to virtual robot controls (SIL)
Signal communication in virtual-time
Peripheral resources with kinematic and simple behavior models
What is required to achieve
targets? Accurate robot behavior
configuration-, turn handling, …
Accurate motion planner
Signal communication
with peripheral resources (i.e. clamps)
between robots
How to achieve?
Viewer
OPC-UA
Solver
Logic
Mechanics
Dynynics
Material flow
Collision
Shares MemoryShares Memory
External
OPC-UA
PLC Program Validation• Targets• Understand required functionality
• Test the functionalities during development process
• Increase software quality before commissioning phase
• Reduce time of virtual commissioning
• Purpose
Create the PLC programs, using the 3D simulation model to communicate the required functionality and to validate the programs
• Logic programs
• Safety programs
PLC Program Validation
Simulation model with simple behavior model for all actors
Simulation model directly connected to Soft-PLC or alternatively to real PLC
What is necessary to achieve
targets? Signal communication in virtual-time
Structure, functionality and behavior of simulation model identical to real production equipment
How to achieve?
External
OPC-UA
Kernel
Viewer
OPC-UA
Solver
Logic
Mechanics
Dynynics
Mat. Flow
Collision
Shares Memory
Shares Memory
Virtual Commissioning
• Targets
• Test complete functionality
• Find out and fix malfunctions
• Increase software quality
• Reduce risk for commissioning
• Reduce effort for following service phase
• Purpose
Virtual factory acceptance test to validate all real controls, connected to the 3D simulation model instead to the real production equipment.
• Robot and CNC programs
• PLC logic and safety programs
Virtual Commissioning
• How to achieve?
• Simulation model with physical behavior model for all actors
• Simulation model directly connected to fieldbus, for real time communication
• What is required to achieve targets?
• Signal communication in real-time
• Connection of hardware controls (HIL)
• Structure, functionality and behavior of simulation model identical to real production equipment
Virtual Commissioning
Viewer
Real
Kernel
Shares Memory
OPC-UA
Solver
Logic
Mechanics
Dynynics
Material flow
Collision
Shares MemoryShares Memory
Real Time
Fieldbus
In order for Virtual Commissioning
to work, the virtual 3D components
must react to the true PLC programs,
the identical way that real components
would react
Challenges
• Data Security – More Access Points
• Proprietary Production Knowledge – IT Security Risk
• Need for High Degree of Stability to sustain Cyber-Physical Communication
• Difficult to maintain integrity of production process w/ less human oversight
• Resistance – perception of job loss
• Lack of Experience and Manpower overall to implement such highly advanced process Forbes Magazine
Overall Benefits
• Flexible Automation – Production Complexity can be Handled
• Potentially Safer with less Human interaction in cells
• Better control of supply chains with data at every level of the process
• Time – Faster Time to Production with Virtual Commissioning
• Self Correcting Smart Cells
• Industry 4.0 = Connectivity between equipment and the “digital twin”, which allows for greater overall productivity. This directly translates to time and cost savings.
Forbes Magazine
Thank You
Lee Van EverySenior Account Executive
CENIT North America691 N. Squirrel
Address 2
Auburn Hills, MI,
USA
Telephone: 248 309 3243
Email: [email protected]
www.FASTSuite.com