Arc's Dick Slansky & Greg Gorbach's Virtual Commission Workshop @ 2009 ARC Industry Forum
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Virtual commissioning is the use of 3D simulations to validate production systems prior to physical implementation. It allows manufacturers to create virtual production facilities to optimize and validate real-world manufacturing processes. Key benefits include substantially reducing product launch timelines and costs. Effective virtual commissioning requires integrated mechanical, electrical, and control system simulations. While simulation technology enables virtual commissioning, organizations must invest in device libraries and determine the right cost-benefit tradeoffs for their individual capabilities and needs. Overall, virtual commissioning can save money and speed time to market.
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Arc's Dick Slansky & Greg Gorbach's Virtual Commission Workshop @ 2009 ARC Industry Forum
- 1. Virtual Commissioning:Virtual Commissioning: Validation Through VirtualizationValidation Through Virtualization Greg Gorbach Vice President Dick Slansky Senior Analyst, PLM ARC Advisory Group ggorbach@arcweb.com y , ARC Advisory Group dslansky@arcweb.com
- 2. What is Virtual Commissioning?What is Virtual Commissioning? • Definition: Virtual Commissioning (VC) is the use of a virtual model that represents an accurate and realistic 3D simulation of mechanical electrical and control systemssimulation of mechanical, electrical, and control systems in order to validate the operation of a production system prior to actual physical implementation. • VC Tools Provide a Unified Platform for Mechanical Design, Electrical Design, and Control Data in an Integrated Data Model • VC Platforms enable Component Reuse for Building Automated Production Systems through Mechanical & Electrical Models, and Controls Programming TemplatesElectrical Models, and Controls Programming Templates • VC Focuses on the Validation of Manufacturing Processes rather than Product Design 2 © ARC Advisory Group • VC is Not Discrete Event Simulation, and is not focused on Production Process Throughput
- 3. Virtual Commissioning Benefits/DriversVirtual Commissioning Benefits/Drivers • Addresses one of Manufacturing’s Fundamental Issues: Getting Product to Market in a Timely and Competitiveg y p way • The general trend toward shorter product lifecycles is driving the importance of the production ramp up to adriving the importance of the production ramp-up to a new model’s economic success in the market • Substantially Reduces the Product Launch Lifecycle • Allows manufacturers to create complete virtual production facilities in order to optimize and validate their real world manufacturing processesg p • Virtual Commissioning Eliminates many of the Time and Resource Consuming Tasks that otherwise must be Physically Performed by Controls Engineers 3 © ARC Advisory Group Physically Performed by Controls Engineers
- 4. Where is Virtual Commissioning in the Lifecycle Model Innovation/ Concept ProductProduct Design K l d Maintenance & Support Virtual Design Virtual Support Collaborative PLM Hub Knowledge Capture & Reuse Shop Floor Systems Virtual Production PLM Hub Automation Systems Engineering Production Product Testing Mfg Process Production Process Simulation Virtual Testing Virtual Build 4 © ARC Advisory Group g ocess Design Virtual Commissioning
- 5. Virtual Build: Simulating ManufacturingVirtual Build: Simulating Manufacturing Virtual Build Physical Build AutomationMfg Process Design D il Pl i Production Process Simulation • Automation Platform • Control Code Generation • Detail Planning • Assembly & Installation Plng • Work Instruction Generation • Tooling & Assembly Process • Virtual Workcell • Robotic Simulation 5 © ARC Advisory Group Virtual Commissioning
- 6. ARC Product/Process/Production Model PLM Design and Engineering Components Technology Infrastructure Data Management (Collaborative PDM Core) Supply Chain D&E Collaboration Product Design & Engineering Operations Management A li ti Infrastructure Product Innovation Management Mechanical, Electronic, Embedded Software Production Asset Applications Simulation & Validation Production Ramp-Up Equipment Supplier Collaboration Process Innovation Management Mfg Process Design & Engineering Mechanical, Electrical, Controls, Software Commissioning Digital ManufacturingManufacturing Where VC fits within the Context of ARC PPP Model 6 © ARC Advisory Group
- 7. Design the Production Process Mechanical, Electrical, Software Design the Production Process Mechanical, Electrical, Software Control DesignMfg Process Modeling D i DESIGN Software Design Manufacturing Process, System, & Components Design Automation PlatformExecution Visibility Controls Interface Control Logic Schematic Design Panel Design ECAD I/O BlockSensor Drive Electrical Design Conveyor Design Workcell Design Safety MCCHOA Mechanical Design MCAD Conveyor Design Workcell Design RobotConveyor CAD, 7 © ARC Advisory Group Production Cell Design CAD, etc
- 8. Virtual Commissioning Validating the Design; Validate the Planned Installation Virtual Commissioning Validating the Design; Validate the Planned Installation DESIGN Software Design Manufacturing Process, System, & Components IMPLEMENT Software System Build, Test, & Deploy Physical System Control Validation HMI VALIDATE Execution Visibility Controls Interface Control Logic MES EMI Execution Visibility HMI Controls Interface Controller Control Logic I/O BlockSensor Drive Electrical Design I/O BlockSensor Drive Electrical System Electrical Design Validation Production System Validation Safety MCCHOA Mechanical Design Safety MCCHOA Mechanical System P d ti S tW k C ll RobotConveyor CAD, RobotConveyor Production System Simulation Work Cell Simulation 8 © ARC Advisory Group Production Cell Design CAD, etc Production Cell
- 9. Virtual Commissioning Implementing the Physical Production System Build, Test, & Deploy Physical System Software System EMI Visibility Control Systems PLCs CNCs HMI/Mfg Intelligence MES EMI Execution HMI Controls Interface Controller Control Logic I/O BlockSensor Drive Electrical System Electrical Panels Safety MCCHOA Mechanical System Conveyance Systems Robotic Work Cells Physical Production RobotConveyor 9 © ARC Advisory Group Systems
- 10. Virtual Commissioning Validate the Designed Mfg Process Prior to Implementation Virtual Commissioning Validate the Designed Mfg Process Prior to Implementation IMPLEMENT Software System Build, Test, & Deploy Physical System DESIGN Software Design Manufacturing Process, System, & Components VALIDATE Software System Process, Interference, Kinematics, Controls, etc. n MES EMI Execution Visibility HMI Controls Interface Controller Control Logic Execution Visibility Controls Interface Control Logic MES EMI Execution Visibility HMI Controls Interface Virtual Controller Control Logic ign calInstallation I/O BlockSensor Drive Electrical System I/O BlockSensor Drive Electrical Design I/O BlockSensor Drive Electrical Model OptimizeDesi alidatePhysic Safety MCCHOA Mechanical System Safety MCCHOA Mechanical Design Safety MCCHOA Mechanical & Environmental Model Validate&O missioning:Va RobotConveyorRobotConveyor CAD, Simulation RobotConveyor Environmental Model VirtualComm 10 © ARC Advisory Group Production CellProduction Cell Design CAD, etc Virtual Production Cell Simulation Environment V
- 11. Simulation-Based Design Process Design, Modeling, Simulation, and Virtual Commissioning Simulation-Based Design Process Design, Modeling, Simulation, and Virtual Commissioning Production System Requirements & Conceptual D i VIRTUAL COMMISSIONING Design Design Mechanical Systems Simulate Behaviors 3D Solid Models 3rd party Subsystem, Component, & Device Models Product Models Systems e a o sModels Real-time Simulation Integrate Designs Electrical Design Electrical Systems Electrical Model Emulate the I/O Control Device Models Controller Code Design Control System Validate the Virtual System Generate Control Logic Real or Soft Controller/ HMI 11 © ARC Advisory Group Physical Install Validated Process
- 12. Design Automation Platform ModelDesign Automation Platform Model PHYSICALVIRTUAL ControlMfg Process ESIGN Target PLC or Automation Platform Developed with or by PLC providers PLC Code Generator Control Design Mfg Process Modeling DE p y p d Machine Specific Control Logic LIDATE Production Simulation Validate Controls VAL PLC HMI 12 © ARC Advisory Group OPC Client/Server
- 13. Virtual vs. Actual; Cost vs. Benefit: Options for Virtual Commissioning Virtual vs. Actual; Cost vs. Benefit: Options for Virtual Commissioning Virtual C i i i HIL Virtual C i i i Physical C i i i l / Virtual Plant Real I/O Virtual Product Components Commissioning l / Virtual Plant Real I/O Virtual Product Components Commissioning l / Real Plant Real I/O Real Product Components Commissioning Virtual Field Real I/O Virtual Sensors & Actuators Real I/O Virtual Plant Equipment Virtual Field Real I/O Virtual Sensors & Actuators Real I/O Virtual Plant Equipment Real Field Real I/O Real Sensors & Actuators Real I/O Real Plant Equipment Real I/O Virtual Field Connections i l Real I/OVirtual I/O Real I/O Virtual Field Connections i l/ h i l Real I/OI/O Emulation Real I/O Real Field Connections h i l Real I/OReal I/O Controller Hardware-in-the-Loop (HIL): The production equipment is simulated, b h ll l Real I/O Virtual Controllers Real I/O Virtual/Physical Controllers Real I/O Physical Controllers 13 © ARC Advisory Group but the controllers are real
- 14. Importance of Modeling Electrical DesignImportance of Modeling Electrical Design • Enables Complete Diagnostics Validation • Enables Virtual Commissioning for Safety System (PLCs,Enables Virtual Commissioning for Safety System (PLCs, Light Curtains, Sensors, etc.) • Provides Environment for Fault Recovery Testing l d f d• Eliminates modification to PLC Logic: Provides Accurate Emulation of Control Logic Connection to I/O tags • Virtual Commissioning is not Feasible without theg Integration of Electrical Models • Modeling an integrated Electrical & Mechanical Production System Provides a Complete TestingProduction System Provides a Complete Testing Environment for Control Engineers • Provides the Best Value Proposition for Using VC 14 © ARC Advisory Group
- 15. Virtual Commissioning Benefits & TradeoffsVirtual Commissioning Benefits & Tradeoffs Simulation Environment • 3D Simulation for Mechanical Design of Production SSystems Electrical Model • Panels & Schematics Design• Panels & Schematics Design Validation of Virtual or Physical Controller • Software & Hardware Validation Virtual Validation of HMI • OPC Client/Server Validation MES d Mf I t lliMES and Mfg Intelligence • Validation of Shop Floor Systems & Visualization I/O Emulation 15 © ARC Advisory Group I/O Emulation • Validation of PLC tags to I/O Blocks
- 16. SummarySummary Available simulation technology enables virtual commissioning todayvirtual commissioning today … but much work remains for the user • Build/maintain device libraries, etc.Build/maintain device libraries, etc. … and cost/benefit tradeoffs must be made to maximize the value to your company based on individual capabilities and circumstances Virtual Commissioning Can Save Money and Speed Time to Market 16 © ARC Advisory Group
- 17. Thank You.Thank You. For more information, contact the author at dslansky@arcweb.com or visit our web pages at www arcweb com 17 © ARC Advisory Group www.arcweb.com