Arc's Dick Slansky & Greg Gorbach's Virtual Commission Workshop @ 2009 ARC Industry Forum

Virtual Commissioning:Virtual Commissioning:Validation Through VirtualizationValidation Through Virtualization

Greg GorbachVice President

Dick SlanskySenior Analyst, PLM

ARC Advisory [email protected]

y ,ARC Advisory [email protected]

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

Virtual Commissioning Benefits/DriversVirtual Commissioning Benefits/Drivers

• Addresses one of Manufacturing’s Fundamental Issues: Getting Product to Market in a Timely and Competitive g y pway

• 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


Physically Performed by Controls Engineers

Where is Virtual Commissioning in the Lifecycle Model

Innovation/Concept

ProductProduct Design

K l d

Maintenance & Support Virtual

DesignVirtual 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


g ocessDesign

Virtual Commissioning

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


Virtual Commissioning

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 & EngineeringMechanical, Electrical, Controls, Software

Commissioning

Digital ManufacturingManufacturing

Where VC fits within the Context of ARC PPP Model


Design the Production Process Mechanical, Electrical, SoftwareDesign 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,


Production Cell Design

CAD, etc

Virtual CommissioningValidating the Design; Validate the Planned InstallationVirtual CommissioningValidating the Design; Validate the Planned Installation

DESIGN

Software Design


IMPLEMENT

Software System

Build, Test, & Deploy Physical System

Control Validation HMI

VALIDATE

Execution

Visibility

Controls Interface

Control Logic

MESEMI

Execution

Visibility

HMIControls Interface

ControllerControl Logic

I/O BlockSensor Drive

Electrical Design


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


Production Cell Design

CAD, etc

Production Cell

Virtual CommissioningImplementing the Physical Production System


Software System

EMIVisibility

Control Systems

PLCs CNCs HMI/Mfg Intelligence

MESEMI

Execution




Electrical System Electrical Panels

Safety MCCHOA

Mechanical System Conveyance Systems Robotic Work Cells

Physical Production

RobotConveyor


Systems

Virtual CommissioningValidate the Designed Mfg Process Prior to Implementation

Virtual CommissioningValidate the Designed Mfg Process Prior to Implementation

IMPLEMENT

Software System


DESIGN

Software Design


VALIDATE

Software System

Process, Interference, Kinematics, Controls, etc.

n

MESEMI

Execution

Visibility



Execution

Visibility

Controls Interface

Control Logic

MESEMI

Execution

Visibility


Virtual ControllerControl Logicig

n

cal In

stal

lation


Electrical System


Electrical Design


Electrical ModelO

ptim

ize

Des

i

alid

ate

Phys

ic

Safety MCCHOA

Mechanical System

Safety MCCHOA

Mechanical Design

Safety MCCHOA

Mechanical & Environmental Model

Val

idat

e &

O

mis

sionin

g:

Va

RobotConveyorRobotConveyor

CAD, Simulation

RobotConveyor

Environmental Model

Virtu

al C

om

m


Production CellProduction Cell Design

CAD, etc

Virtual Production Cell

Simulation Environment

V

Simulation-Based Design ProcessDesign, Modeling, Simulation, and Virtual CommissioningSimulation-Based Design ProcessDesign, 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

ElectricalDesign

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


Physical Install

Validated Process

Design Automation Platform ModelDesign Automation Platform Model

PHYSICALVIRTUAL

ControlMfg Process

ESIG

N Target PLC or Automation Platform

Developed with or by PLC providers

PLC Code Generator

ControlDesign

Mfg ProcessModeling

DE p y p

d

Machine Specific Control Logic

LID

ATE

ProductionSimulation

ValidateControls

VAL

PLC HMI


OPC Client/Server

Virtual vs. Actual; Cost vs. Benefit:Options for Virtual CommissioningVirtual 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/OVirtual Product Components

Commissioning

l /Virtual Plant

Real I/OVirtual Product Components

Commissioning

l /Real Plant

Real I/OReal Product Components

Commissioning

Virtual Field

Real I/OVirtual Sensors & Actuators

Real I/OVirtual Plant Equipment

Virtual Field

Real I/OVirtual Sensors & Actuators

Real I/OVirtual Plant Equipment

Real Field

Real I/OReal Sensors & Actuators

Real I/OReal Plant Equipment

Real I/OVirtual Field Connections

i l

Real I/OVirtual I/O

Real I/OVirtual Field Connections

i l/ h i l

Real I/OI/O Emulation

Real I/OReal 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/OVirtual Controllers Real I/OVirtual/Physical

Controllers Real I/OPhysical Controllers


but the controllers are real

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 the gIntegration 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


Virtual Commissioning Benefits & TradeoffsVirtual Commissioning Benefits & Tradeoffs

Simulation Environment• 3D Simulation for Mechanical Design of Production

SSystemsElectrical 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


I/O Emulation• Validation of PLC tags to I/O Blocks

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


Thank You.Thank You.For more information, contact the author at

[email protected] or visit our web pages atwww arcweb com


www.arcweb.com

Arc's Dick Slansky & Greg Gorbach's Virtual Commission Workshop @ 2009 ARC Industry Forum

Technology

Transcript of Arc's Dick Slansky & Greg Gorbach's Virtual Commission Workshop @ 2009 ARC Industry Forum