flexible anlagengestaltung und –vernetzung zur umsetzung ... · virtual commissioning benefits of...

© Fraunhofer IFAM

Automation and Production Technology, Stade, Germany

Tim Haß

Fraunhofer IFAM

Fraunhofer IFAM

Automation and Production Technology

Head of Department: Dr. Dirk Niermann

Forschungszentrum CFK NORD

Ottenbecker Damm 12 | 21684 Stade

www.ifam.fraunhofer.de

© Fraunhofer IFAM

Klebtechnik und Oberflächen

AGENDA

Digitalization

3DExperience at Fraunhofer IFAM

Current Applications

Offline Programming and Simulation

Virtual Commissioning

Planned Applications and Future Goals

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Digitalization

Drivers of Digitalization

Source: BCG, Roland Berger

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Integrated Platform for Robotic Applications

Integrated process development

Cross disciplinary engineering

Immersive environment for robot programming, robot simulation and validation of robot tasks

Workcell layout calibration

Support for advanced logic

3DExperience

Behavior Model

Kinematic Model

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Construction of a Virtual Working Cell Robots from library

Customjigs, tools,machinery

Productgeometry

Factory environ-ment

CAD models including kinematics:

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Approach and Objectives

12

34

Geometry preperation& curve selection

Tag generation

Robot path generation

Robot programcreation

Simulation &Upload to robot

CAD data

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Project NFM-Glare

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Realistic Robot Simulation (RRS)

Increasing simulation accuracy

Optimized robot trajectories

Accurate motion planning

Accurate cycle-time simulation

Motion control software implemented from real robot controller (RCS module)

High accuracy processes

Limited space in working area

Multi-Robot simulation and manipulators with various DOF

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Virtual Machine Model

Kinematic simulation: geometry, position, robot axes and joints, inverse kinematic model, collision analysis

Behavior simulation: sequencing, IOs, bus configurations, motion behavior

Plant Controller

Original real controller/PLC

Virtual model of controller/PLC Simulated or emulated PLC

Interfaces between Machine Model and Plant Controller

Use of industrial communication interfaces

Compliance with communication protocol and cycle time synchronization


Implementation

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HiL and Full-System Simulation

+ Simulation of models with high complexity

+ No predefined time limits for communication

Limited availability of controller models

Not suitable for real time use

Test of real behavior not assured

Hardware-in-the-Loop Simulation

Full-System Simulation

+ Realistic test of controller systems

+ Real time communication

+ Variable cycle time synchronization depending on level of simulation (process, machine, facility)

Simulation of models with high complexity requires high computing power

Source: Georg Wünsch


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Communication Protocol

Virtual Machine Model in 3DExperience

Kinematic Model

Original PLC

Behavior ModelHMI

PLC Interface

Control Panels

OPC UA

Interface for data transfer from real plant controller to virtual environment in 3DExperience

Communication via OPC UA

Data gathering between virtual model in 3DExperience and real PLC


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Signal Exchange with PLC

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Benefits of Virtual Commissioning

Increasing software quality - debugging PLC code in a virtual environment before downloading it to the real equipment

Reducing the actual commissioning time

Optimization of processes

EngineeringManufacturing

and Assembly

Engineering

Modelling

Manufacturing and Assembly

Commissioning

CommissioningFacility Control


Time

Without virtual commissioning

Virtual commissioning

approach Time

reduction(Effort)

Earlier realization of rework and changes


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Adaption of Systems Engineering methods

Development with the RFLP approach

Application of Model-Based Systems Engineering (MBSE)

Creation of a interconnected, cross-disciplinary system model

Enhancement of the virtual environment

More realistic simulation / Additional tools

Enrichment with additional data

Implementation of different use cases

Topics

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Virtual product development based on Systems Engineering and RFLP

RequirementsEngineering

FunctionalDesign

LogicalDesign

PhysicalDesign

ComponentTesting

Integration

Verification

Validation

Source: :em

R

F

L

PMechanics

Electronics Software

Requirements

Engineering

Data

Simulation

Results

System Analysis

Requirements

Functional Architecture

Logical Architecture

Component Specification

System Integration

Simulation

Test

System Development

M-CAD

E-CAD

CAE

Behaviour Models

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Model-Based Systems Engineering

RFLP

Software

SystemArchitecture

PLM

Processes

Documentation

BOM

MultiphysicsSimulation

CAD

Digital Mockup

Ergonomics

Kinematics

STEPAP233

CAESystem

Model

ComputationalFluid Dynamics

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Increase realism of the simulation withadditional tools and workbenches

Simulation of physical behaviour

Use case:

Simulation of stringer deformation withSimulia/Dymolia and the physics engine

Fluid flow simulation and application ofadhesives, sealants, coating etc.

Optimized robot paths based on thesimulation results

Usage of different Simulation Tools in the3DExperience Platform

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Possibility of path or geometryadjustments in 3DX based on sensorinformation

Use case:

Determination of the current position andgeometry of parts and toolsExamples:calibration of the end-effector TCP,position and measurements of parts

Real time path adjustment based on externally computed path (calculatedfrom camera information)

Implementation of Sensor Data in the 3DExperience Environment

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Implementation of different kinematicmodels of various industrial robots

Custom kinematics include: Kuka iiwa, Fanuc hexapods, six axis portal roboticsystem, mobile robots,...

Implementation of User Defined Kinematics

Use case:

Generation of complex paths for theadhesive application on aircraftcomponents with a six axis portal roboticsystem

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Automated Cabin and Cargo Assembly

Robot assisted assembly with automated guided vehicles

Digitilization of manual and cooperative processes

Simulation of human – robot collaboration

Use case:

Assembly of hat racks, side panelsand other components inthe fuselage

Cooperative mobile robotsand human workers in aconfined space

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1 …

2 …

3 …

4 …


Simulation of Cooperative Robot Processes and Human Ergonomics

Evaluation of productivity and ergonomics

Verification and process optimization

Risk evaluation

Source: IFA

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