In Part 4 of our blog series, we tackle one of the most critical challenges in virtual commissioning: ensuring that virtual models truly reflect real-world systems. While simulation offers immense benefits, its true value lies in its accuracy – if the virtual and physical systems don’t align, costly errors can arise. In this post, we’ll explore how manufacturers can bridge this gap, ensuring that digital models behave exactly as their physical counterparts would in a real production environment.
Don’t miss the video from the Realize Live session, where experts demonstrate how continuous validation ensures virtual models align perfectly with real-world production systems.
At the Realize Live event, Colm Gavin shared insights into how manufacturers can optimize automation through simulation and virtual commissioning. Now, we’ll dive deeper into the core elements of virtual commissioning. We will discuss how these simulations help overcome common challenges in the manufacturing world.
Virtual Commissioning in Bridging the Gap Between Simulation and Reality
One of the most significant challenges in virtual commissioning is bridging the gap between simulation and reality. Discrepancies between the virtual models and their real-world counterparts can lead to trust issues, delays, and operational failures. To mitigate these risks, virtual commissioning must ensure that the virtual systems behave in precisely the same way as the physical ones.
At the Realize Live event, Gavin discussed the importance of keeping the virtual and real systems synchronized. This synchronization requires ongoing validation throughout the commissioning process, ensuring that no discrepancies arise between the two. Whether it’s the control logic, electrical components, or mechanical movement, virtual commissioning must account for all variables to guarantee that the system operates as expected once implemented.
The Virtual Machine Model: A Comprehensive Approach
The Virtual Machine Model is the cornerstone of virtual commissioning. This model integrates automation, electrical, and physical simulations to create an accurate virtual replica of the production system. Let’s break down each component:
- Automation Model: This model simulates the control logic and behavior of the system, often implemented through a PLC. Engineers can test the PLC logic and simulate the operator interfaces to ensure that the system operates as intended before it is physically implemented.
- Electrical Model: Unlike many other simulation tools, Siemens Tecnomatix goes a step further by providing granular electrical simulations. The electrical model includes drives, valves, and sensors, along with their interactions with other components in the system. By simulating electrical behaviors, engineers can ensure proper function and identify issues that could arise in real-world implementations.
- Physical and Kinematic Model: This model represents the mechanical elements of the system, including machines, robots, and conveyors. It simulates physical movements and interactions, allowing manufacturers to optimize workflows, reduce cycle times, and minimize mechanical failures.
Validation of the automation logic against a physical, kinematic or robotic model
The integration of all three models – automation, electrical, and physical – creates a seamless, real-world simulation. However, the key challenge here is ensuring that the virtual model accurately mirrors the behavior of the physical system.
As virtual commissioning continues to evolve, the focus must remain on precision. Ensuring that the digital twin is not just a representation but a true-to-life model of the physical system. By leveraging advanced simulation tools and continuous validation, manufacturers can eliminate discrepancies, enhance efficiency, and build greater trust in virtual commissioning.
In the next installment of our series, we will explore key challenges in the automation industry. It will be shared by our Vice President of Technology, Tengyuan Zhang. Stay tuned for expert insights on overcoming these challenges and driving the next wave of innovation in manufacturing!
If you haven’t checked Blog 3 in this series, check it now: Virtual Commissioning: Optimizing Production from Line to Machine Level.
