simulation-based engineering and virtual commissioning on ... · fanuc heidenhain rockwell siemens...

© ISG Industrielle Steuerungstechnik GmbH 2017 2017-11 ISG-virtuos-Präsentation-2017engl.pptx

Simulation-based engineering and virtual commissioning on virtual components

The double for your stars Simulation-based engineering and virtual commissioning in control realtime (1ms)


Expertise – Technology and know-how

2

ISG Industrielle Steuerungstechnik GmbH

Dr.-Ing. Dieter Scheifele

Field of business ISG-kernel (since 1987)

Control software CNC, RC, Motion Control

Clients Control, machine and plant manufacturers

Field of business ISG-virtuos (since 2005)

Simulation software Virtual commissioning as hardware-in-the-

Loop in control realtime (1ms),

Digital twins

Clients Machine and plant manufacturers,

Engineering offices (integrators),

Plant users

~ 10.000 machines of different technologies / per year


ISG-kernel – CNC, RC and Motion for complex kinematics

3

Copyright WAFIOS AG 2016


Digital twin – Configured with virtual components

4

Features

Virtual machine / plant

configured with virtual

components

Behaviour of virtual

components regarding

interfaces, parameters and

operations modes parallel real

components

Virtual commissioning with

reproducible response times in

control realtime (1ms)

including SAFETY

Easy engineering by using

original engineering data

Real controls

Beckhoff

Bosch

B&R

Fanuc

Heidenhain

Rockwell

Siemens

…

Real fieldbusses

CANopen

EtherCAT

Ethernet IP

Focas

Powerlink

Profibus

Profinet

OPC UA

…

Digital twin

© ISG Industrielle Steuerungstechnik GmbH 2017 2017-11 ISG-virtuos-Präsentation-2017engl.pptx 5

„best practice“ – Customers and partners


„best practice“ – Customers and partners

6


„best practice“ – Plant and mechanical engineering

7

HEITEC AG

Short commissioning times and

optimum software quality

Test of extreme situations without

any risks

Re-use of mechatronic modules

Generation of improved approval

criteria

Optimization of service and

maintenance

Training and qualification of staff

By courtesy of HEITEC AG


„best practice“ – Digital twin / Factory simulation, HOMAG

8

By courtesy of HOMAG Group


„best practice“ – Packaging, KOCH Pac-Systeme

9

By courtesy of KOCH Pack-Systeme GmbH


„best practice“ – E-Pass, EISENMANN SA

10

By courtesy of EISENMANN SA

E-Pass, EISENMANN SA


KraussMaffei

Machine and plant engineering in the

field of injection molding machines

Requirements

Detailed test of various client

configurations

Electric and hydraulic machine

clamping force up to 54.000 kN

Result

Process control via control of virtual

models in control realtime (<1ms)

Automated configuration of control and

simulation model according to sales

order

Simulation (logics, kinematics,

dynamics (hydraulics)) of every

delivered machine

„best practice“ – Injection molding machines, KraussMaffei


Simulation system


Simulation system – Real commissioning on virtual machines

14

Features

Commissioning of real

CNC/PLC/RC on virtual systems

including field bus (HILS)

Reproducible response times in

control realtime (1ms) including

SAFETY functions

Real time deterministic

behaviour of the virtual machine

on the CNC/PLC/RC field bus

Interfaces for the Integration of

offline programming systems

„simulation based engineering“

thanks to using original

engineering data

Reale Steuerungen

Beckhoff

Bosch

B&R

Fanuc

Heidenhain

Rockwell

Siemens

…

Reale Feldbusse

CANopen

EtherCAT

Ethernet IP

Focas

Powerlink

Profibus

Profinet


Simulation system – Control realtime

15

Requirements of ISG-virtuos clients on control realtime (1ms)

Tendancy: SPS cycle times are continuously getting shorter (2, … 4ms)

The reason is not the increased computing power but the automation tasks

enabled by the increased computing power:

Process control including in-process-measuring

(Measurement of time-critical process factors, movement synchronization such as „flying saw“, …)

Test of control methods via simulation of control and disturbance variables (clamping forces during

gripping and joining processes, process technology, vast disturbance scenarios, …)

Synchronization of drives of motion and CNC controls (high demands on tact syncronization, …)

Simulation of drive modules (time-critical „state machines“ as field bus participants)

Functional safety

(Reaction time on switch-off processes in safety modules, …)

Grown demands on result reproducibility

(cycle time exact comparison of process values via deterministic realtime, …


Simulation system – Virtual components for automation

16

Fieldbus

Real control Real fieldbus participant Real components with

realtime behaviour

Real machine / plant (Components, overall behaviour, material flow)

Virtual machine / plant (Components, overall behaviour, material flow)

Configuration

Configuration

Virtual components

with realtime behaviour

Real fieldbus participant

1:1 Reproduction of components and configuration process

„virtual

clamps“

Emulation

1:1 (I/O, Drives, Safety …)


Simulation system – Services with virtual realtime components

17

HILS (fieldbus)

Real control Virtual component Fieldbus participant

Fieldbus

(Multislave)

Virtual plant

Virtual plant

IT-Network

connection

OPC UA

TPC/IP

… Projection

CAM systems …

Cloud services

WEB

services

Intelligent services

Virtual technology objects


Simulation system – Platform for realtime applications

18

Commissioning with real controls in control realtime

System modelling from component libraries

3D visualization by means of original 3D CAD data including configuration

Control panels for the verification of processes and test of disturbance szenarios

Realtime simulation kernel with reproducible results, e.g. for regression tests

Control connection with identical I/O configuration just as on real systems

Real fieldbus

Real controls

Real

machine

Simulation PC

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Kinematics

Dynamics

MF

Realtime simulation kernel (solver)

Realtime operating system (1ms)

Fieldbus

(Slave)

System interfaces

PC operating system (MS-Windows 64-bit)

3D visualization Test panels Modelling


Reales Automatisierungssystem

Simulation system – Continuous engineering processes

19

Model-in-the-Loop

(MIL)

Software-in-the-Loop

(SIL)

Projection

Design of plant layouts

Generic and

hardware independent

description of control task

Prototypical control code

Thread testing and

program generation

Offline programming

Emulated, i.e. virtualized

control

Generation of control code

as serial code (e.g.

according to IEC61131-3)

Standard communication mechanisms

OPC UA

TCP/IP …

Shared Memory

Real controls with real control

code

Real HMI including all user

interactions

Real fieldbus systems

E.g. Profibus, Profinet, EtherCAT

Including safety

No „Gateways“

Virtual plant / machine from virtual components

Kit system for behaviour models and 3D visualization

Process simulation / material flow

Removal simulation / collision detection

Virtual components

Behaviour models and 3D visualization strictly separated

Realtime deterministic behaviour of virtual components (1ms)

1:1 connectable as fieldbus participant (same addressing, behaviour including safety)

System / Process

HMI

Controls

Communication

Profinet

EtherCAT

…

Components

Sensors / Actors

Hardware-in-the-Loop

(HIL)


Simulation system – Integration of engineering tools

20

Projection and programming tools

Engineering tools Virtual commissioning

Real fieldbusses

Real controls

SDK C++

Realtime solver

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3D visualization Test panels

Modelling

Module

library

Integration platform

KUKA office lite

FANUC Roboguide

ABB RobotStudio

EKS RobSim

…

Offline programming systems Projection and layout

ISG CNC.sim

IFF Vincent

CENIT FastSuite

…

Standard interfaces (UDP, OPC, TCP/IP)


Simulation system – Unique features

21

Criteria Solution with ISG-virtuos

Platform The ISG-virtuos runtime environment runs on industrial control platforms

Simulation in hard deterministic control realtime < 1ms

Motion library for control functions

Fieldbus

connection

ISG-virtuos is a real field bus participant (Profibus, Profinet, EtherCAT, CAN …)

Control uses original addressing and timing

(no non-realtime-able gateway to Windows is necessary)

Different field busses can be combined

Safety Functional control safety can be tested

Safety simulation for I/O and drives

Safety simulation modules for Profibus, Profinet, EtherCAT

Material flow Libraries with material flow including processing simulation

Removal simulation and collision detection

Material handling during process (separate/sawing, mate, wire, rolling …)

Engineering ISG-virtuos disposes of an open engineering platform for realtime applications

Software Development Kit for realtime applications (SDK C++)

Integration and automation interfaces (OPC, ROS, XML, CAD- and E/A-Import..)


Simulation system – Solution for established control systems

22

Auszug CNC


Simulation system – Heterogenous automation scenarios

23

Simulation of plants / machines with complex automation structures

Use of real controls of different manufacturers at the same time

Connection via different fieldbusses at the same time

Transfer of master E/A configuration via EtherCAT, Profibus, Profinet

Integrated safety modules

EtherCAT

Profibus

Profinet …


Simulation system – complex, distributed production systems

24

Continuous test / Simulation of complex automation solutions

Simulation system easily extendable via fieldbus mechanisms

Combination of Hardware-in-the-Loop simulation and real automation systems

Superior 3D-visualization of the entire plant

„Factory Acceptance Tests“ already during commissioning


Engineering process


Engineering – Simulation-based engineering

26

Objective / Features

Conversion of inflexible,

sequential processes into agile

„systems engineering“

Software engineering including

commissioning as leading

process

Virtual plant / machine is

constantly available for

dimensioning tests and

optimizations

Failure situations are considered

from the very beginning

Virtual commissioning can be

transferred without limitation on

the real machine / plan

Systems Engineering

Processes

Functions

Failure scenarios

Mechanics

Electrical design Provision

Mounting

Delivery

Ramp-up

FAT

Real plant

/ machine

Virtual plant / machine

Software engineering / Commissioning

Clients

Requirements

Service

agile engineering


Engineering – Virtual commissioning – Development potential

Development potential Future need for simulation tasks

Share of companies with a growing or strongly growing need for simulation tasks


Engineering – Agile processes with virtual components

28

3D-CAD system

(mech. construction)

Mechatronical components

(mech. / electrical construction)

Control technology

(software, commissioning)

3D visualization

(motion, processes)

Behaviour

(logics, kinematics,

material flow…)

Production processes, failure

situations

(signals, fieldbus participants,

drives…)

Rea

l c

om

po

nen

ts

Vir

tual

co

mp

on

en

ts


Engineering – Structuring the machine into functional units

29

Fieldbus participants for:

EtherCAT 1) SW

Profibus 1) HW

Profinet 1) SW

CANopen HW

Ethernet-IP SW

1) Including safety functionality Real machine / function units

Real / virtual behaviour

Identical machine behaviour

Fieldbus

Real / virtual fieldbus participants

Virtual machine / function units


Engineering – Visualization (direct import of 3D CAD data)

30

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 components library


Engineering – Component models (from component libraries)

31

Features

Company-owned library as Know-

How set-up and protection

Validated part- / sub models

Efficient engineering by re-use

Process optimization by

automated model generation

Real component Virtual component

Configuration 1

Solution / Know-how library Configuration n


Engineering – Generation of virtual components

32

3. Virtual components including symbolism

1. Modelling of component behaviour 2. Parameter definition

4. Integration into library

Components library


Engineering –Virtual components (e.g. hydraulics / pneumatics)

33

Component library


Engineering –Virtual components (e.g. control including position controller)

34

PI controller Control path of 2nd order Position

set value Position

actual value

Components library


Material flow – Physics-based in control realtime

35

Automotive / Assembly units

Material flow in handling processes Logistics

Conveyor technique

Pick-and-Place applications

Features

Realtime deterministic behaviour

(no „windows scripting“)

Vast libaries for efficient engineering

Machining simulation and collision

detection included


Material flow –Module library

36

Seamless integration in ISG-virtuosM and ISG-virtuosV

Existing library with standard modules

Easy modelling thanks to consistent architecture, procedure and

interface

Subsequent amplification of existing models

Easy linking onto control signals

Fully automatic visualization of the modelled scene

Material flow elements

Guided transportation

SKID (conveyor-based) transportation

Handling

Sensors

Storage technique


Material flow –Component-based modelling

37

Behaviour of material flow elements

Writing devices determine behaviour of material flow

elements and material

Reading devices identify the element characteristics

Writing and Reading devices are connected to the

material flow elements via uniform interfaces

The behaviour can be changed by subsequently

adding further devices

Benefit

Comprehensibility thanks to standardized modules

with in- and outlets

Clarity, since only relevant characteristics are

modelled

Subsequent amplification of existing models

Device

Writing

Device

Reading

Element

Material flow


Material flow –“Elements“ from module libraries

38

Transportation Handling Sensing Material Pools & Storing


Material flow –“Devices“ from module libraries

39

Actuators Transportation (Motors) Measurement

Writing Attributes


Material flow – Simulation models from modules

40

Additional value

Easy understanding of the model

behaviour on the basis of the block

diagram (no programming / scripting)

Automatic model generation by

simple configuration process

3D visualization available „on one

click“

Overlap of CAD- and material flow

element geometries possible

High rack

storage are

Derailleur Rack

feeder

Corner

transfer

conveyor

Photo

sensor

Linear

conveyor


Material flow – System test (handling / processing)

41

KUKA CNC - HMI

ISG-virtuos – Test scenario

ISG-virtuos – 3D visualization and removal simulation

ISG-virtuos – plant model


Engineering – Removal simulation and collision detection

42

Removal simulation

Precise, photo realistic presentation

Work progress in realtime

Collision detection

Definition of body pairs

Collision display and signal


Engineering – Configuration from the module kit system

43

Plant / machine Function areas

Function units Configurable modules (video) By courtesy of Weeke

Bohrsysteme GmbH


Engineering – Connecting controls via real fieldbusses

45

Automation by way of example Siemens/PROFINET (comparable for PROFIBUS and EtherCAT)

1. Generation of SIMATIC S7-Project (Master)

Add stations (e.g. SIMATIC 300 station)

Add compatible CPU (e.g. CPU 319F-3 PN/DP)

Choose Ethernet interface IP address and establish subnet

Add/establish PROFINET tools (e.g. ET 200S, PN/PN coupler)

2. Export master configuration (*.cfg) and

respective tool master file data (*.gsdml)

3. Generate ISG-virtuos project (multi slave)

Import master configuration (*.cfg) via I/O-Wizzards

Import tool master file data (*.gsdml)

Generate project with I/O tool image

Select I/O ports that need to be simulated (mixed mode possible)

Generate solver task with linkage on the tool I/Os

4. Simulation with virtual ports as field bus participants

Connect virtual I/Os in ISG-virtuos and control (only once)

Start simulation and effect virtual commissioning

Export

Import

*.cfg GSDML

S7

Ma

nag

er

Master

Add project-specific

informations (FU,

pos.-drives)

ISG

-vir

tuo

s

I/O-Wizard

Multi-Slave


Engineering – I/O-Wizard for S7 Manager and TIA Portal

46

Siemens – S7 Manager

Export Import

*.cfg

GSD

S7

Ma

nag

er

Master

ISG

-vir

tuo

s

I/O

-Wiz

ard

Multi-Slave

Siemens – TIA Portal

Import ASCII

GSD

TIA

Po

rtal

Master

TIA Konverter

Openness V14

ISG

-vir

tuo

s

I/O

-Wiz

ard

Multi-Slave

Profinet

Profibus

Profinet

Profibus


Engineering – Connecting models and I/O ports

47


Engineering – Modelling of drive axes

48

Modelling of drive axes

Quick access thanks to eligible

modelling depth

Goal: „As simple as allowed for the specific

simulation task“

Bypass : „Set = Actual“

PT1 / 2 : Delay resp. oscillation ability

Control structure with more than 30

parameters

Link to MATLAB/Simulink


Engineering – Software Development Kit (SDK C++)

49

Benefits

Realisation of own modules also for

realtime applications in C++

Open automation platform

Executable in TwinCAT 3.1

Fast familiarization with developer

manual


Engineering – Automation of test scenarios

50

Test environment =

real control technology

Client systems

Engineering

Virtual

module library Engineering

assistance

(user-oriented)

Automation

(Generators, …)

Adaption of ext.

systems

(Translator /

mapping)

Grafic support

Process generators

(Motion, IOs)

Construction data

Part lists

Layout

3D CAD data

Mechanical

modules

Electric

components

Behaviour models

Control

functionality

ISG-virtuos

ISG-kernel

VirtuosM (behaviour model)

E/A configuration

Model configuration

Control configuration

Control software

E/A configuration

Client (AB) /

Production

VirtuosV (3D visualization)

Geometry (3D)

Collision detection

Removal simulation

Client-specific

interfaces / formats

Real

modules

XML


Engineering – Automated tests with digital twins

51

Features

Configurable test system for HILS systems (plant

manufacturers and users)

Automatic and reproducible system tests (resp.

Software regression tests)

User can create vast test scenarios including

logging

Connectivity to superior systems (e.g.

requirements management)

Digital twin flexibly adaptable to changes in the

plant configuration (basis: virtual components)

Automated test system for system tests

Real fieldbusses

Komponenten Bibliothek

Inkl. Testfeatures

reale Steuerungen

digitaler Zwilling (ISG-virtuos / HILS)

Test scenarios

Requirement management

Test protocolling

Regression tests

FAT documentation

… Test library

Test

serv

ices

In

terf

aces

Real controls

Digital twin (ISG-virtuos / HILS)

Component

library

incl. test features


Virtual commissioning in control realtime

52

We happily support you in implementing

simulation technology in your company.

By means of an introductory workshop,

we check the specific requirements for the

precise realization of your project at short

notice.

Virtual commissioning helps to achieve:

simulation-based engineering and virtual commissioning on ... · fanuc heidenhain rockwell siemens...

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