The realtime simulation software for Virtual commissioning · 2019-11-20 · Simulation software Simulation platform for virtual commissioning (VIBN) and digital twins in deterministic

1 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos

The realtime simulation software for

Virtual commissioning

Stuttgart, den 20. November 2019

Open simulation platform Real commissioning on virtual models


Simulation platform | Commissioning on virtual models

Virtual commissioning and digital twin

Test automation with digital twins

„best practice“ use cases

Modelling and model generation


Expertise | control technology + simulation platform + test automation

ISG Industrielle Steuerungstechnik GmbH

CEO Dr.-Ing. Dieter Scheifele

Business area ISG-kernel (since 1987)

Control software CNC, RC, Motion Control

Customers Control manufacturers,

Machine and plant manufacturers

Business area ISG-virtuos (since 2005)

Simulation software Simulation platform for virtual commissioning (VIBN) and

digital twins in deterministic realtime (1ms)

Customers Machine and plant manufacturers

Integrators / Machine users

Business area ISG-dirigent (since 2018)

Test automation automated test of control software

in target hardware in connection with digital twins

Customers Machine and plant manufacturers

Integrators / Plant users

~ 15.000 Maschinen unterschiedlicher Technologie per anno


Industrielle Steuerungstechnik GmbH | The ISG-Team

5 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-kernel

CNC, RC and Motion | Functionality for complex kinematics

Copyright WAFIOS AG 2016

6 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-kernel

KUKA-CNC | Robot control with CNC functions

Example: KUKA.CNC processing plastic pipes

Source: Eugen Riexinger D / Weholite UK / KUKA


Best practice


Best practice | Users and partners


Best practice | Virtual commissioning on digital twins

Requirements of our „best practice“ users and partners

System / production test including safety

Quote: "... We do not require a scenic flight but rather a professional flight

simulator with a real cockpit, with which the failure of propulsion systems

including emergency landing can be simulated“

Digital Image of real modules / components

Quote: „ ... the availability of a plant is not only determined by bottlenecks, but

also by irregular operating modes, dynamic parameterisation of

components and their real-time behaviour"

Digital twins as „shadow systems“

Quote: „ ... as operators we need a digital image of the real plant, where real

production scenarios can be simulated on the basis of real production

data".

Digital value creation process

Quote: „ ... the real added value or supply chain for components, assemblies

and means of production must necessarily be supplemented by digital added

value".


Best practice | Digital twin / factory simulation, HOMAG

With friendly permission of HOMAG Group Link to video: https://www.youtube.com/watch?v=9l6pP1imWhw

https://www.youtube.com/watch?v=9l6pP1imWhw


Best practice | Plant and mechanical engineering, HEITEC AG

Added value

short commissioning times and

optimum SW quality

Test even extreme fault situations

without risks

Reusability of mechatronic

modules

Generation of improved

acceptance criteria

Optimization of service and

maintenance

Training and further qualification of

employees

With friendly permission of HEITEC AG

Link to video:

https://m.youtube.com/watch?list=PLC0Ynysv43XTcwEWB75NjzBZMT7nnMoi8&v=I9Vj9jNAqBE

https://m.youtube.com/watch?list=PLC0Ynysv43XTcwEWB75NjzBZMT7nnMoi8&v=I9Vj9jNAqBE


Best practice | Packaging, KOCH Pac-Systeme

With friendly permission of KOCH Pack-Systeme GmbH Link to video: https://m.youtube.com/watch?v=PxOK465OqOA

https://m.youtube.com/watch?v=PxOK465OqOA


Best practice | Training concept, ZF Friedrichhafen AG

Objective

Training and further qualification

of employees on the digital twin

Optimization of service and

maintenance

Reference for suppliers of new

assembly cells

mobile

devices

With friendly permission of ZF Friedrichshafen AG, Schweinfurt


Virtual commissioning and digital twin


VIBN | Use of simulation technology


VIBN | Potential of simulation technology


VIBN | Requirements from the engineering process

Survey

Simulation techniques such as

FEM investigations are mainly

used in early engineering

processes

Commissioning represents the

critical process (completion and

quality of the control software)

Software development (rather

programming) is part of the

commissioning process

Commissioning in plant and

mechanical engineering requires real

production scenarios with real

components and failure situations

Beschaffung

Montage Mechanik

Delivery

Start of production

FAT

Software / Commissioning

„only the SW is missing“ Elektrik

Real plant /

machine

Team „technology“

Ideas

Layout

Modules

Customer

Requirements

Commissioning

including

SW development

Digital engineering

tools


VIBN | Requirements from the engineering process

Measures / solutions

Plant or machine is "virtually"

already available at the beginning

of the engineering process

SW development including

system test with real fieldbuses

and control real-time

Fault and error situations are

taken into account in the

production scenarios

Systems Engineering

Processes

Functions

Failure situations

Mechanics

Electrical design Delivery

Start of production

FAT

Real plant

/ machine

Virtual plant / machine

Software engineering including commissioning

Customer

Requirements

Service

Agile engineering

Provisioning

Assembly

Virtual modules

Composition of

reusable virtual

modules (libraries)


Simulation platform | HIL system test

Features

Configuration of the virtual

machine/plant from virtual

components

Behaviour of virtual components

with regard to interfaces,

parameters and operating modes

like real components

Virtual commissioning with

reproducible response times in

control real time (1ms) including

SAFETY

Real controls

Beckhoff

Bosch

B&R

Fanuc

Heidenhain

Rockwell

Siemens …

Real fieldbusses

CANopen

EtherCAT

Ethernet IP

Focas

Powerlink

Profibus

Profinet

Digital twin


Simulation platform | HIL – complex, interlinked production systems

Requirements on virtual

„Factory Acceptance Tests“

Test of all requirements on real production data

Test of interaction with higher-level host computers /

systems

Consideration of the behavior of all fieldbus

participants

System diagnosis with regard to cycle times, product-

specific output

Production line

Manufacturing

cell

Transport facility

WZM

SPS SPS CNC

Fieldbus system

Host

computer

Unit S1 Unit S2 Unit S3 Unit S4 Unit S1 Unit S2 Unit S3

Optional

systems diagnosis

SPS SPS

CNC

Fieldbus system

Host

computer

Complex HIL factory simulation using

segmentation and real-time coupling

Fieldbus coupling

Fieldbus Fieldbus

Fieldbus

Unit S4


Simulationsplattform | HIL – Fieldbus components for VIBN

Fieldbus

Real control Real fieldbus participant Real components with

realtime behaviour

Real machine / plant

(Components, Over-all behaviour, material flow)

Virtual machine / plant

(Components, Over-all behaviour, material flow)

Configuration

Configuration

1:1 component image 1:1 (I/O, Safety …)

Deterministic realtime

Virtual components

with realtime behaviour

Real fieldbus participant

„virtual

clamps“

Emulation


Simulation platform | SIL - Software-in-the-Loop

Coupling of virtual controls with digital twins

(selection)

Robot controls

KUKA OfficeLite

ABB RobotStudio

FANUC ROBOGUIDE

…

PLC / CNC

SIEMENS S7-PLCSIM Advanced

SIEMENS SINUMERIK One

Beckhoff TwinCAT

ISG kernelv

…


Simulation platform | MIL - Model-in-the-Loop

Integrated engineering process

1. Project planning - design / configuration of the system

2. Concept development - definition of interactions through "teaching" and verification of processes

3. CODE generation - Control Projects in IEC61131

4. Virtual commissioning - in control real time 1ms, including safety on the

5. Qualification of the control software - software regression tests including fault scenarios and fieldbus

6. Digital Twin - Scenes for service support and operator training


Simulation platform | Open simulation platform - USP

Real automation system

HMI

Controls

Communication

Profinet

EtherCAT

…

Components

Sensors / Actors

Plant / Process

va

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Flexible Simulation platform for virtual commissioning

Real control

Model-in-the-Loop

(MIL)

Software-in-the-Loop

(SIL)

„Motion generation “ generic and HW-

independent description of

the control task

Simple project planning of

motion sequences

Concept tests on the basis of

construction

prototype control code

Virtual control

Offline proramming

Emulated, i.e. virtualized

control

Generation of control code

as serial code (e.g.

according to IEC61131-3)

Standard Communication mechanisms

Shared Memory

OPC UA

TCP/IP …

Real controls including real

control code

real HMI including all user

interactions

Reale fieldbus systems

E.g. Profibus, Profinet, EtherCAT

Including Safety

No „Gateways“

Virtual plant / machine made of virtual components

Modular system for behavior models and 3D visualization

Process simulation / material flow

Material removal simulation / collision detection

Virtual components

Behavioral models and 3D visualization strictly separated

Realtime deterministic behavior of virtual components (1ms)

Can be connected 1:1 as fieldbus participant (same addressing, same behaviour including safety)

Hardware-in-the-Loop

(HIL)

Sim

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Ste

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Sim

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Ste

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Simulation platform | open, extendable simulation platform

Project planning and programming tools

Engineering Virtual commissioning

Real fieldbusses

reale Steuerungen

SDK C++

Realtime solver

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3D visualization Test panels

Modelling

Module

library

Integration platform

KUKA office lite

FANUC Roboguide

ABB RobotStudio

…

Offline programming systems Project planning and layout

SIEMENS PLCSIM Adv.

SIEMENS SINUMERIK One

BECKHOFF TwinCAT

Standardschnittstellen (OPC-UA, TCP/IP)

OPC-UA Client

TCP/IP-Treiber

SYS / DLLs

…

FMI / FMU

MIL / SIL

HIL

Real controls


Simulation platform | real & digital (virtual) value added chain

Platform and processes

Platform

Test automation

Research facilities

Plant manufacturers (VIBN, Engineering)

Portfolio

Implementation Workshops

Simulation libraries

Consulting (technology

and processes)

Applications

Plant real & virtual for VIBN and production optimization …

Plant users

* shown: direct users „digital shadow + modelling“

Components real & virtual for VIBN / digital twins

Framework SDK C++

Implementation support

Component suppliers


Modelling process Virtual modules


Modelling process | virtual (mechatronic) modules


Modelling process | 3D visualization

3D visualization 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 component library


Modelling process | Generation of virtual components / modules

Real modules

Configuration 1

Module library Configuration n

Modelling / component

library

Real components SDK C++

Virtual modules


Modelling process | Connecting control systems

Example: Siemens – TIA Portal / S7-Manager

TIA

Po

rtal

I/O master configuration

ISG

-vir

tuo

s

1. Transfer of the master configuration including the corresponding device master data GSD(ML)

2. Generation of the fieldbus participants ("emulated clamps”)

Generation of the realtime project with emulated terminals (I/O-Multi-Slave as fieldbus participant)

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

3. Connection of the real control via the real fieldbuses

original addressing and the same fieldbus clock time (e.g. 1ms)

all virtual clamps are implemented as fieldbus participants (including I/O safety)

Import

GSD

TIA Converter

Openness

I/O-Wizard

I/O-Multi-Slave

Profinet

Profibus


Modelling process | Behaviour models

„z.B. Pneumatikachse“

Function units

„ Retract_axis“

„ Extend_axis“

Control outputs

„Axis_extended“

„Axis_retracted“

Control inputs

Chain of action between

I/Os

?


Modelling process | Module test

Control and indicate Virtual modules Module library


Projection V2.8 – Projection from the modular system

35

Features

User level for generating simulation scenarios as 3D layouts

TwinStore component library with virtual components and individual customer modules

Generation of the simulation scene including behavior models via drag&drop and snapping functions

Default sequence for fast visualization of processes as Model-in-the-Loop (MIL) simulation

Directly transferable to VIBN with real or virtual controls (SIL and HIL)


TwinStore | Online platform for simulation models for VIBN

Features

Simulation library, component library and Co-

Simulation library for ISG-virtuos

Models certified by ISG

Model templates for fast projection of customer-

specific digital twins

Models directly from component suppliers and

simulation specialists

Added value

Constantly growing range of functions through

the involvement of component manufacturers

and users

Efficient modeling through the use of mature

components including configurable templates

More detailed models due to implementation

by component manufacturers

ISG-virtuos TwinStore

Libraries

Supplier

License management

Simulation specialist

Coordinated technology

specific simulation models,

expert models

Machine and plant manufacturer

Digital twin of machine / plant

Component supplier

Digital twin of component

Certification / Quality assurance

Norming and

standardisation

Simulation

library

Component

library

Co-Simulation

library

Documentation

Exemplary projects

Models

Provisioning Import


TwinStore | Online platform (contents, example)


VIBN / Simulation platform | Economic benefit

Saving potentials (Average scores, customer survey)

20% REDUCED

PRODUCT DEVELOPMENT COSTS AND TIMES

80% REDUCED

COMMISSIONING TIMES

10% OPTIMIZED

PLANT PERFORMANCE

30% REDUCED

PROJECT COSTS

NEW SERVICES

$ AVOIDABLE CULANCES

and GUARANTEES

VIBN

Product engineering

Production

Design and development

Service

39 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-dirigent

Test automation Process optimization in engineering


Test automation | Development

Test on the real plant

▼ can only be carried out after completion of the plant

▼ extends the delivery time of the plant

▼ Risk of damage to the system

▼ error-prone due to human factors

Test with real controls on virtual plants (HILS)

can be carried out before delivery of the system

extensive and safe tests, even of malfunction situations

▼ high time expenditure for extensive test scenarios

▼ error-prone due to human factors

Automated test with real control on virtual plants

increased software quality due to increased test scope

reliable results by excluding human error

reproducible test results including logging

can be integrated into requirements management

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VIBN

CAST


Test automation | Example: Test of measuring cycles


Test automation | Test results

Features

The test result is displayed

transparently in the test plan

A negatively completed test case is

marked in the project structure and

can be found immediately.

For each negative test result, the

cause of the error and the

associated parameters are

displayed.

The test result is logged in

adjustable detailing.

Status for the

entire test plan

Positively completed test

cases

Test error including

cause of error

Negatively completed test

case


Test automation | certifiable test report


T: +49 711 22992-

E:

W: www.isg-stuttgart.de

Dr. Christian Daniel

Business manager simulation technology

53

[email protected]

Documents

The realtime simulation software for Virtual commissioning · 2019-11-20 · Simulation software Simulation platform for virtual commissioning (VIBN) and digital twins in deterministic