Digital twin
Efficient development with simulations and virtual commissioning in mechanical and plant engineering
Faster development and commissioning of machines with simulations
The digital transformation has long since arrived in all branches of industry. With Industry 4.0, the close interlinking of the real and digital worlds offers numerous opportunities that allow the economical use of resources. The challenge of making sensible use of scarce resources while building up the greatest possible knowledge through structured data preparation does not stop at mechanical and plant engineering.
Especially for complex machines, which have a high overall development time, the evaluation of design alternatives and the testing of SPS programs is time-consuming and cost-intensive. With the help of simulation models, real systems can be recreated and used for experiments, thus saving development time and production costs (up to approx. 16%). There are already a large number of simulation environments from different manufacturers in which digital twins can be tested.
The digital machine twin is an overall construction consisting of many individual components. To be able to simulate their behavior as a whole, all integrated components must interact smoothly. To make it easier for our customers to integrate format adjustment processes using positioning systems, we offer standardized model files for our products of the PSx3xx family.
Your benefits by using simulation models:
- The parameters can be easily varied and development alternatives can thus be tested against each other.
- The number of prototypes can be reduced to achieve a reduction in production costs.
- Relevant simulation results are available quickly, saving development time.
- Problematic operating conditions can be simulated without risk and thus avoided in reality.
The simulation models by halstrup-walcher
The FMUs (Functional Mockup Units) from halstrup-walcher are standardized model files that contain an image of the PSx3xx firmware and can be used independently of the simulation environments. They simulate the behavior of the PSx3xx positioning systems and can digitally map format adjustment processes or the response to machine malfunctions. For this purpose, the simulation model can be used to write and read broken-down process data as well as to write further input signals to hardware components or faults. This data can then in turn be read out by the controlled system..
The model files include basic functionalities that can be used free of charge (positioning travel without loop). On request, further functions can be unlocked, such as simulations like loop travel or the behavior in case of disturbances. The FMUs are already available for PSx3xx positioning devices with ProfiNet and Ethernet/IP and are continuously extended with further bus systems and product lines.
Scope of services of FMU by halstrup-walcher
✓ Data-based behavior models as an image of the real positioning systems PSx3xx (based on real operation)
✓ ProfiNet:
Actuation of the simulation component in SIMIT via TIA Portal
Other bus systems: Simulation component for
other simulation environments (without actuation)
✓ Description of the parameters of the simulation model (including variant number of the positioning system, velocity, position)
✓ Input screen for writing and reading the encoded process data (14Byte input and 16Byte output)
✓ Additional inputs for simulation of hardware components and faults (e.g. jog key input, motor voltage, device temperature, bus communication error, blocking error, tracking error)
✓ Further output of the current position in degrees for the connection to the CAD model
The FMUs provided by halstrup-walcher are thus the digital image of the positioning systems used in the machine. Together with the virtual HMI, the control software and the other simulation components, they form the digital twin of your machine design. The comparison of the real environment and the simulation environment is outlined in the following figure.
With the help of the digital twin, it is possible to analyze and optimize the machine design and parameterization. In addition, valuable data on machine behavior can also be collected after production and evaluated over time, facilitating continuous further development of the plant. With the FMUs, halstrup-walcher contributes to an easy integration of the components into the digital twin of the machine.
