the realtime simulation software for virtual commissioning · 2019-11-20 · simulation software...
TRANSCRIPT
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
2 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Simulation platform | Commissioning on virtual models
Virtual commissioning and digital twin
Test automation with digital twins
„best practice“ use cases
Modelling and model generation
3 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
4 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
9 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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".
10 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Best practice | Digital twin / factory simulation, HOMAG
With friendly permission of HOMAG Group Link to video: https://www.youtube.com/watch?v=9l6pP1imWhw
11 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
12 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Best practice | Packaging, KOCH Pac-Systeme
With friendly permission of KOCH Pack-Systeme GmbH Link to video: https://m.youtube.com/watch?v=PxOK465OqOA
13 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
14 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Virtual commissioning and digital twin
16 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
VIBN | Potential of simulation technology
17 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
18 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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)
19 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
20 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
21 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
22 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
…
23 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
24 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Simulation platform | Open simulation platform - USP
Real automation system
HMI
Controls
Communication
Profinet
EtherCAT
…
Components
Sensors / Actors
Plant / Process
va
rio
us
co
nfi
gu
rati
on
s /
co
up
lin
gs
of
rea
l a
nd
vir
tual
sim
ula
tio
n p
art
icip
an
ts
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
ula
tio
nsm
odell
Ste
ueru
ngscode
Sim
ula
tio
nsm
odell
Ste
ueru
ngskonzept
25 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Simulation platform | open, extendable simulation platform
Project planning and programming tools
Engineering 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
…
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
26 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
29 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Modelling process | virtual (mechatronic) modules
30 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
31 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Modelling process | Generation of virtual components / modules
Real modules
Configuration 1
Module library Configuration n
Modelling / component
library
Real components SDK C++
Virtual modules
32 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
33 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
?
34 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
Modelling process | Module test
Control and indicate Virtual modules Module library
35 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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)
36 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
37 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
TwinStore | Online platform (contents, example)
38 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
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
40 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-dirigent
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
ye
ste
rda
y
tod
ay
ne
w
VIBN
CAST
41 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-dirigent
Test automation | Example: Test of measuring cycles
42 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-dirigent
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
43 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-dirigent
Test automation | certifiable test report
45 © ISG Industrielle Steuerungstechnik GmbH 2019 ISG-virtuos
T: +49 711 22992-
E:
W: www.isg-stuttgart.de
Dr. Christian Daniel
Business manager simulation technology
53