b07_Process Simulate Virtual Commissioning
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Transcript of b07_Process Simulate Virtual Commissioning
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Process Simulate Virtual
Commissioning
Shay Shomroni
Director Industry Solutions
Manufacturing Business Group
Page 2
© 2011. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Shop-floor challenges
HMI synch
with tools
Throughput
reaction
Sensor
positioning
Tool
change
procedure
Electrical
device
signals
Safety
procedures
Handling
variants
Conveyor
optimization
Page 3
© 2011. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Virtual Commissioning
Environment for testing, simulation and debug of PLC programs, HMI
code, and automation scheme with a virtual model of a factory
Faster
• Shorter time to production
• Quicker change cycle
Better
• High quality PLC code
• Optimized performance
Less Expensive
• Cost of production stop
• Cost of prototype parts
Page 4
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Story board
OEM XYZ Supplier 123
+
Page 5
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Supplier Analyze: What is required?
Tooling
Clamps and Pose sensors address new variant
Robotics
OEM Standard program considers pedestal gun and new variant
Control
HMI test for clamps, safety procedures and E-Stop pass
Page 6
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
EBZ Case Study
https://sales.industrysoftware.automation.siemens.com/accesscount/188
28/EBZ-Group-Customer-Testimonial-R7T1A1
Page 7
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Primary Line Builder Challenge
Validate OEM changes faster and more accurately
Page 8
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Tooling Tasks
Adaptation of Process, based on existing design
Define clamp functionality and specific behaviour
Mapping to PLC Signals and dynamic testing
Change the existing Process to multi variant
Correct Material Flow
Variant Detection
Mapping to PLC Signals and
dynamic testing
Page 9
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Tool design Example
Page 10
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
OEM instructions
OEM XYZ Supplier 123
Page 11
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
The Use Case: Requirements
Traditional Work cell Simulation
Variants
Safety
Synchronization
Native Language
OEM Standards
Maintenance
Peripheral Resources
Page 12
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Robotics engineers tasks
Manage changes after receiving a new path:
Variant Branching
Synchronize robots to PLC
OEM Standard Robot Code
Download programs and test
Page 13
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Robotic Simulation
Page 14
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Event-Based Simulation
Realistic cycle time
Conveyor control (physical, logics)
Material handling between stations
Load, steady state, variants and shutdown
scenarios
OP 3
OP 2
Time based
OP 1
OP 3
OP 2
Event-based
OP 1
A
NOT A
Page 15
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Supplier Analyze: What is required?
Tooling
Clamps and Pose sensors address new variant
Robotics
OEM Standard program considers pedestal gun and new variant
Page 16
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Control – virtual commissioning
Mechanical Electrical
Kinematics
Robot Programs
Mechanical Sequences
Layout
Clearances
Cycle Time
Inputs / Outputs
Logic
Interlocks
HMI
Diagnostics
Safety
Evaluate Mechanical and Automation System behavior
Page 17
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Easily create a realistic shadow of a production
environment
Test & Debug PLC code
Long before the real system is build
Minimize impact on existing environment
Use real PLC H/W or emulated S/W
Start of
Production
Test earlier Don‘t disturb
production
Virtual Commissioning
Page 18
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
VC Environment
Contr
ols
S
imula
tion
Process
Knowledge
OPC (Client & Server)
Signal
Mapping
Real Time
Signal
Exchange
PLC Code
Automation
Validation
Digital Process
Design
PLC HMI
Page 19
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Virtual Commissioning Demo
Page 20
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Life Cycle Processes (Current State)
Equipment Design
Controls Design
Workcell Simulation
Estimating Planning Design Construction
Installation Try-Out Program
Robots Debug
Process Planning & Documentation
Cost and Time
Page 21
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Life Cycle Processes (Future State)
Equipment Design
Controls Design
Workcell Simulation (Enhanced)
Estimating Planning Design Construction
Installation Debug (Physical)
OLP
(Enhanced)
Debug
Process Planning & Documentation
Try-Out
Cost and Time
Page 22
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
AMT Testemonial
https://sales.industrysoftware.automation.siemens.com/accesscount/24847/Virt
ual-Commissioning-Video-AMT-Testimonials-R7T4N3
Page 23
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Benefits
Estimating Planning Design Construction
OEM
Tier 1
Primary LB
Tier 2
Eng Houses
Earlier start of production
Lower cost on changes
Major Risk reduction:
Mature processes
Right the first time
Standardization of processes and components
Collaborative and Efficient Engineering
Validation reduces risks on site
Page 24
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Process Simulate Take Aways
Highly functional & easy to use
Widely deployed by OEMs and LB
Natural upgrade of Robcad
Connected to TC backbone
Proven value and customer benefits
Page 25
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
THANK YOU!