virtual commissioning for machines with nx mechatronics ... · virtual commissioning for machines...

Virtual Commissioning for machineswith NX Mechatronics Concept Designerand SIMATIC Machine Simulator

Realize innovation.

Jochen MerhofNX Product Manager – Mechatronics Concept DesignerProduct Engineering Software / Germany / New Markets

[email protected]

Unrestricted © Siemens AG 20182018-10-30 Siemens PLM Software

NX: Breaking down the barriers to innovation

Electro-Mechanical Design

Most Productive Modeling Environment

Generative Design & Integrated Validation

Industrialized Additive Manufacturing

Collaborative Design Management

Immersive Design with VR

Flexible ProductDevelopment

Platform

Unrestricted © Siemens AG 2018

Siemens’ production machine businessis proud technology partner for machine builders

SIMATICSIMOTION

SINAMICSdrives

SIMOTICSmotors

ApplicationCenter

SoftwareDigitalization

Packaging Printing Plastics Textile Metal Forming

Wood Glass Renewables Converting Handling

Digitalizationchangeseverything ”

The next trillion dollars will beearned with data – for our customersand for our industries.

Michael Dell, founder of Dell Inc.”Digital is the main reason just overhalf of the companies on the Fortune500 have disappeared since the year2000.

Pierre Nanterme, CEO Accenture


Our customers have essential requirements –throughout the manufacturing industry

Security

Speed Flexibility Quality Efficiency


Digitalization will penetrate the entire production systemlife cycle with IT for more productivity and a shorter time-to-market

1 2 3 4 5ProductionPlanning

MachineEngineering

MachineCommissioning

MachineOperation

MachineService

Life cycle of production systems


How can digitalization find the best machine concept thatfulfillsthe production planer requirement?


MachineEngineering


MachineOperation

MachineService

Challenges for the mechatronic engineer

What is the basic kinematicdesign?

Which machine modulesare needed?

Can I use a digital twin forconcept design and reuseit for CAD afterwards?


Mechatronic Concept Designer – The productivity can beassessed at early concept phase of machine developments

Digital Twin• Definition of machine modules• Definition of kinematic• Rough design• Sequencing of operations• Motion profiles (Cams)• Simulation of kinematic

Benefit• Verification of concept through

simulation in an early state• Assessment of the productivity

Design of machine concept for the Multi-Carrier-System (Optima) as an example

Example MCS


To realize customer demands faster, Bausch + Ströbelfocuses on significant increase of efficiency by using digitaltwinsDigital Twin• Concept design with NX MCD of a

filling machine for syringes• Further reuse of the digital twin for

NX CAD up to virtualcommissioning

Benefit• Faster development through early

concept verification• Increased flexibility and productivity• Lower the engineering effort by 30%

in 2020

Digital twin of packaging machine in NX for pharma industry

“Our driver for Digitalization is ourconviction that it will bring addedvalue to the customer”

Dr. Hagen GehringerCEOBausch + Ströbel, Ilshofen


How can digitalization make sure that the machinehas been build and setup properly?


MachineEngineering


MachineOperation

MachineService

Challenges for the commissioner when the machine has been build

How can I make surethat all components(mechanics, electric,software) interplayproperly?

How can I make sure bestreliability and avoid anymalfunctions likecollisions?

Can I further optimize themotion functions or PLCprogram to further improveproductivity?

Simatic® Machine Simulator


How can digitalization make sure that the machinehas been build and setup properly?

3 MachineCommissioning

Challenges for the commissioner when the machine has been build

1 2 4 5ProductionPlanning

MachineEngineering

MachineOperation

MachineService

• SIMIT• NX MCD• PLCSimAdvanced


Automation Hardware

Commissioning at the real machine causes costs and risks

Real Machine

Real Machine

Diagnosis withTIA-Portal

HMI

• Fieldbus• I/O

In Out


Hardware-in-the-loop virtualizes the behavior of the realmachineto reduce costs and risk of commissioning

Automation HardwareDiagnosis withTIA-Portal

HMI

• Field bus• I/O

In Out

Behavior model of• Sensors• Actuators• Process features• Temperature• Pressure• Hydraulics• Pneumatic

Kinematic model for• Motion• Material flow• Collision check

Position of axes

Virtual machine on separated PC


Software-in-the-loop with PLCSIM Advanced will furtherreduce the effort and improve the reliability of virtualcommissioning

Control emulation withPLCSIM Advanced

Behavior modelwith SIMIT• Sensors• Actuators• Process features• Temperature• Pressure• Hydraulics• Pneumatic

Kinematicmodel withMCD• Motion• Material flow• Collision check

Position of axes

SIMATIC S7-1500 Machine Simulator: Available Tools for virtual commissioning

• Interface of I/O scan tobehavior model

• Output of motionposition/speed

• Time management• Common

startup/shutdown/failurehandling

• Input/Output• Axis position and

speed

1 2

3


Hardware-in-the-loop versus Software-in-the-loop

SIMATIC Machine Simulator: always ready to simulate

Hardware-in-the-loop Software-in-the-loop

• Real Automation Hardware is used• Decentral Periphery is emulated within

special simulation unit hardware• Machine is simulated as digital twin• Real-time simulation needed

• Automation Hardware is emulated asSoftware

• Decentral Periphery is emulated withinbehavior modelling tool as software

• Machine is simulated as digital twin• Simulation speed can be adapted to

slow motion or fast motion


Managed simulation of all involved components

SIMATIC S7-1500 Machine Simulator: ready to mange simulation progress


Advanced modern Couplings between the involvedcomponents

SIMATIC S7-1500 Machine Simulator: easy to handle

Coupling Setupand

Import of Signals

2 clicks only!


Included libraries - reduce engineering time costs and risks

SIMATIC Machine Simulator: easy modelling with included library blocks


Virtual commissioning at MAKA Systems: The digitaltwin enabled a previously not feasible delivery period

Application:• Customer had issues complying the delivery period for the plant

with his own capabilities

• Solution via digital twin: Using MCD, SIMIT and customer's data(CAD/STEP, S7 hardware-configurations and operationalsequence description) it was possible to realize development andsimulation of the machine operation sequence parallel

Benefit• Drastically decreased time effort (time for machine

commissioning -85%, parallelization saved 5 weeks)

• Mechanic issues localized and solved prior to the commissioning• Delivery period accomplished

Door production line from MAKA Systems:Digital Twin using Mechatronic ConceptDesigner (MCD)


1 2 3 4 5MachineCommissioning

MachineOperation

MachineService

Benefits and next steps on virtual commissioning

Geometry and Kinematic

Hardware configuration Tag list

1 2 3 4ProductionPlanning

MachineEngineering


MachineOperation

“Saving 3 weeks at shop floor, HiL prevented us from one big andone small crash, we found errors in PLC code (missing alarms…)”1)

• Testing at no risk of machine damage (e.g. due tocollisions), no health risk for the operator

• Commissioning can be done in parallel to productionof the machinery. Thus shortens the Time-to-Market!

• No costs for machines, space, energy, operator,lubricants etc.

• Failures can be tested as well --- e.g. failures ofsensors, miss operations

• Optimization possible, thus best productivity andreliability can be made sure

• Seamless data flow reduces model creation effort

1) Customer quote, translated


Outlook: Physical process behavior --- e.g. for the fillingprocess --- can be simulated with AMESIM

Application• Optimization of filling machines

performance• Improvement of the filling valves

design

Benefit• Higher performance

• Reduced numberof prototypes by 20 percent

• Shorter-time-to-market

Filling machine of Ronchi Mario

Filling machine and its digitaltwin with drives, pipes, valvesand flow

“If you are interested in the global parameters of the system, a 1D simulation tool, such as LMSImagine.Lab Amesim, is the best option, because it is fast, reliable and easy-to-use.”, GabrielePastrello, R&D Engineering at RONCHI MARIO

Thank you.

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