Faults are inevitable during the development of a machine or plant. However, they can
cause high costs and enormous effort when they are only detected during real
commissioning. Integration in a line or plant involves risks as well. A solution is simulation with TIA Portal. Based on the digital twin of a new machine or line you’re able to parallelize engineering, test functions and detect faults earlier, simulate the interplay of the machine in a line, and optimize operation while its running. Also, additional services can be offered based on the digital twin of the machine, which can also be used for marketing, i.e. at fairs or in a virtual showroom.
Source : Siemens Virtual Commissioning
Machine builders and plant engineers, system integrators and plant operators have different requirements. Simulation provides a number of benefits in any case. In order to make best use of it, we’re providing specific solutions for each use case.
In order to fully digitalize a machine, it’s necessary to virtualize its three essential elements: automation, electrics, and mechanics. SIMATIC S7-PLCSIM Advanced represents the virtual controller based on the SIMATIC S7-1500 and is required for simulation of the controller software. An open interface lets you connect the virtual SIMATIC controller to a variety of other simulation tools. An example is SIMIT, which represents the electrical behavior. In order to complete the digital twin of machine it’s necessary to include and simulate mechanics and kinematics. This is a task for NX Mechatronics Concept Designer.
Before integrating a machine into a production line, it’s possible to validate the interplay of a superimposed controller with robots and the creation of complete robot programs. This facilitates the design of cells and the validation of workflows in complex manufacturing lines with many interacting robots.
The virtual line comprises several simulation models: a discrete event-oriented simulation model that simulates material flow. A communication model that comprises interfaces to automation and third-party tools. And an automation model that enables to simulate a controller.
Simulations are also useful to optimize machines during operation. This way you can realistically verify and validate the automation in complex mechatronic systems and processes, even if the hardware configuration isn’t finished yet. Fast simulation cycles and synchronization also enable optimizing the control strategy including closed-loop applications like PID controllers.