Test methodology for virtual commissioning based on behaviour simulation of production systems

Sub, Sebastian; Magnus, Stephan; Thron, Mario; Zipper, Holger; Odefey, Ulrich; Fäßler, Victor; Strahilov, Anton; Kłodowski, Adam; Bär, Thomas; Diedrich, Christian

doi:10.1109/etfa.2016.7733624

Cited by 20 publications

(3 citation statements)

References 8 publications

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“…Fig. 1 The basic configuration of virtual commissioning [24] In terms of the logic signals processed, the digital twin can be divided in terms of the size of the simulated objects. In the case of the manufacturing systems design domain, the two main objects are the manufacturing machine and the manufacturing system.…”

Section: Development and Methods Of Virtual Commissioningmentioning

confidence: 99%

The Role of a Behavioural Model for the Virtual Commissioning of Robotic Manufacturing Systems

Skýpala

Ružarovský

2022

Research Papers Faculty of Materials Science and Technology Slovak University of Technology

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This paper focuses on virtual commissioning of a robotic manufacturing system, its theoretical background, and an analysis of its importance in the design of automated and robotic systems. Virtual commissioning allows the PLC control program to be tested and debugged on a created digital model of the machine, called a digital twin of the machine. Just this solution can simulate and optimize the automated system design itself without the need to have real hardware (PLC, automation elements, or the whole machine/equipment). Virtual commissioning offers an effective alternative to reduce the risks and effort of real commissioning of the machine. This makes it possible to reduce the time to market and increase flexibility, efficiency, and quality. Virtual commissioning in a single-control system is a simple solution; we can either use the Software-in-the-Loop method with emulated PLC control, simulated behavioural model, and co-simulation model or Hardware-in-the-Loop method with real controller. The problem appears when we have various types of controller, including an industrial robot controller. The paper deals with the theoretical background and partial outlines of solutions in the use of different types of the control system, if interconnections or emulators for different control systems are available. The recommended solution is to use a separate solution for the 3D simulation of the robotic system and an independent solution for the behavioural model, which will be tested in the future.

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Section: Development and Methods Of Virtual Commissioningmentioning

confidence: 99%

The Role of a Behavioural Model for the Virtual Commissioning of Robotic Manufacturing Systems

Skýpala

Ružarovský

2022

Research Papers Faculty of Materials Science and Technology Slovak University of Technology

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“…The advantage of this approach in VC is that it can detect collisions undetected with conventional simulation technologies. Also using VC, [15] applied it both in the first commissioning of the engineering stage and after product changes in the production stage. This approach defines behavior models to describe the behaviors of each resource in the manufacturing system.…”

Section: Related Workmentioning

confidence: 99%

Manufacturing 4.0: Checking the Feasibility of a Work Cell Using Asset Administration Shell and Physics-Based Three-Dimensional Digital Twins

Nguyen,

Huang,

Keith

et al. 2024

Machines

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Feasibility checking is a step in manufacturing system engineering for verifying the normalization and effectiveness of a manufacturing system associated with a specific configuration of resources and processes. It enables factory operators to predict problems before operational time, thus preventing equipment and machinery accidents and reducing labor waste in physically organizing the shop floor. In Industry 4.0, feasibility checking becomes even more critical since emerging challenges, such as mass personalization, require reconfiguring work cells quickly and flexibly on demand. Regarding this need, digital twin technologies have emerged as an ideal candidate for practicing feasibility checking. Indeed, they are tools used to implement digital representations of manufacturing entities that can constitute a digital environment and context. Factory operators can test a manufacturing process within a digital environment in different contexts before the execution with physical resources. This approach currently receives significant attention from the manufacturing community; however, there is still a lack of sharing experiences to implement it. Thus, this paper contributes a methodology to engineer a digital environment and context for a manufacturing work cell using AAS digital twins and physics-based 3D digital twins technologies. Technically, this methodology is a specific case of N-DTs, a general methodology for engineering heterogeneous digital twins. The product assembly line case study, also presented in this paper, is a successful experiment applying the above contributions. The two methodologies and the case study can be helpful references for both public and private sectors to deploy their feasibility-checking frameworks and deal with heterogeneous digital twins in general.

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“…Barth et al mention that VC makes it possible to test major incidents such as cable breaks or sensor failures but do not provide specific solutions [17]. Süß et al test the movement performance of a robot and check interference among different mechanical structures with an accurate error-free virtual model, also without considering errors in VC [23]. Schneider et al verify the system with regard to application scenarios as well as unexpected behavior in case of failure [24].…”

Section: General Literature Reviewmentioning

confidence: 99%

Towards narrowing the reality gap in electromechanical systems: error modeling in virtual commissioning

Kuhn

May²,

Liu

et al. 2022

Prod. Eng. Res. Devel.

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Digital factories and smart manufacturing systems have been increasingly researched and multiple concepts were developed to cope with prevailing ever-shortening life-cycles. The ubiquitous digital twin, despite many definitions, is often praised for accurate virtual models. One key idea to improve manufacturing through such virtual models is virtual commissioning (VC), aiming at early machine code validation. VC and its virtual models are still lacking behind their real counterparts. This gap between reality and its virtual model, commonly termed reality gap, increases the complexity of creating cyber-physical systems. An especially stark contrast is visible between the idealized virtual model and a real machine encountering errors. While error simulations exist in other fields of research, a thorough investigation in VC is missing. Thus, this paper addresses the task of narrowing the reality gap in VC based on two steps. First, a comprehensive body of research of possible errors encountered in virtual commissioning is analyzed. Secondly, the feasibility of error implementation is discussed. This paper lays the foundation for narrowing the reality gap and enabling test automation and digital twin-based control.

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Test methodology for virtual commissioning based on behaviour simulation of production systems

Cited by 20 publications

References 8 publications

The Role of a Behavioural Model for the Virtual Commissioning of Robotic Manufacturing Systems

The Role of a Behavioural Model for the Virtual Commissioning of Robotic Manufacturing Systems

Manufacturing 4.0: Checking the Feasibility of a Work Cell Using Asset Administration Shell and Physics-Based Three-Dimensional Digital Twins

Towards narrowing the reality gap in electromechanical systems: error modeling in virtual commissioning

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