Closing The Gap Between Planning And Operation

From the conception of machines and systems to commissioning and acceptance by the customer: The simulation platform ISG-Virtuos enables machine and system builders to carry out complex simulations and 3D visualizations in real time: This enables users to develop new concepts for industry Test 4.0 and implement it quickly, inexpensively and in optimal quality.

Real-time simulation

The ISG-Virtuos simulation solution for simulation in real-time control (1 ms) is already being used successfully in the area of ​​virtual commissioning and for service support. Companies are increasingly using the solution to design new, customized systems or machines. Alternative system concepts can be checked and the data and knowledge obtained can also be used for simulation and 3D visualization. The design phase and virtual commissioning thus merge seamlessly - the break between system planning and operation is eliminated.

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Integrated engineering process for Industry 4.0

In the development phase, the simulation model takes into account all areas involved and accompanies the system throughout its entire product life. Thanks to new standard interfaces, configuration tools and offline programming tools can be seamlessly integrated into ISG-virtuos. This is how users benefit from an integrated engineering process: With networked production units and an integrated engineering platform, companies increase the efficiency of their production and reduce costs at the same time.

Control tests with virtual components

The control functionality for different production scenarios does not have to be tested and optimized on the real system - often according to the "trial and error" principle - with regard to the requirements and fault scenarios. Instead, the controls can be connected to the simulation system via fieldbuses (hardware-in-the-loop simulation) in order to test the interaction between CNC and machine with regard to quality, performance and critical processes in advance - in real-time control in millisecond intervals.

The results can be transferred without restriction to the real system. The ISG-virtuos library provides, among other things, building blocks for material flow simulation. They are based on real-time algorithms for physics-based simulation and enable the review of complex logistics scenarios even without special knowledge. The current version of the software is also equipped with a software development kit (SDK C ++), which enables users to independently develop and test individual simulation modules. The bespoke building blocks can then be made available in the library in addition to the proven simulation models from ISG. This means that the user or system-specific know-how of a company is also available to other users if required.The offline programming systems from Kuka, ABB and Fanuc can now also be integrated for simulations based on the original systems.

Test production scenarios virtually

With the simulation solution, you can perform reproducible tests, check the commissioning of the controls, perform performance optimizations and virtual factory acceptance tests (FATs) and test production processes with virtual workpieces and real production data. It is also possible to simulate how components behave in the event of a malfunction and how to react to them. Necessary changes or adjustments can also be recognized before the system is set up or converted. The early detection and correction of errors saves follow-up costs, since there are no collisions, malfunctions and operational problems. This enables companies to design their processes dynamically, change their production at short notice and react flexibly to disruptions.Even after delivery, the virtual model is available for testing optimizations and adaptations without blocking or endangering the system.

Flexible engineering processes

Simulation-based engineering enables cross-departmental teams to work together right from the start. The provider accompanies the conception and implementation of the software and works out an optimal solution that the employees can test on virtual components. Thanks to real-time simulation, commissioning times are reduced by up to 80%, which means shorter project throughput and hall occupancy times. In addition, the costs and time required for product developments are reduced by up to 20 percent, while the total project costs are reduced by around 30 percent. Any operating status can be tested with the same manpower, and the connection of the simulated system to higher-level control systems is accelerated.

SPS IPC Drives 2016: Hall 6, Stand 336

* Dr. Christian Daniel, Business Manager Simulation Technology at ISG Industrielle Steuerungstechnik GmbH