Real-Time Simulation Center for Automation Technology… · WinMOD_for_Manufacturing Technology_en.ppt ... • Transparent process behaviour through real time 2D/ 3D-visualizationWinMOD

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Virtual Commissioning of machines and plants

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WinMOD_for_Manufacturing Technology_en.ppt

Virtual Commissioning of machines and plants -

effective preparation and rational use

we use it: for Virtual Commisioning

objectives:

• improvement of software quality

• minimisation of risks at the commissioning

• process optimisation

• process analysis

• reduction of cost through shortening of

commissioning time

www.winmod.de

Virtualized

Machine/Installation

real


Real Automation System

Real-Time Simulation Center for Automation

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Chart Topic

Motivation: Shortening of commissioning time

The concept of the virtualized machine with WinMOD

The way to the virtualized machine with virtualized components

The WinMOD Project

Use:

for software testing

during planning

for training

for service and optimisation

Summary

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3

4

5

6

Overview

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• The commissioning of PLC-software

can be performed parallel to the

fabrication.

• The software certification

takes place before the real

commissioning.

• The software is really done before the

real commissioning starts.

• The real commissioning is concentrated

on parameterisation and optimisation.

• An early training of operating personnel is

possible.

advantages of the

virtual commissioning

Motivation: shortening of commissioning time

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The problem: softwaretest with or without the real machine

• software developer is testing individually

• no transparency to third persons

• no influence through the employer

• small test depth

• thereby non-detected risks at the real

commissioning

• test possibilities are limited by the running

machine

• endangering of equipment

• test depth is not enough

• limited time, because dates of delivery have

to be meet

• commissioning time will be exceeded

softwaretest without the real machine

softwaretest with the real machine

problems

problems

real automation system

real machine

real automation system

reale machine

HMI PLC

? HMI PLC

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the virtualized machine

replaces

the real machine

The solution: virtual machines / plants

Advantages

• no changes of the software necessary

• processing of input- and output signals in

real time

• high planning security by shortening of the

commissioning time

• simulation with real PLC hardware

components

• use of existing 3D-design data to virtualize

the machine/installation behaviour

• simulation of disturbance reaction without

endangering of the real

machine/installation

HMI SPS

Virtualized


real


Real Automation System

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The concept of a virtual machine

• The virtualized machine is a real time

simulation of the real machine behaviour,

connected to the PLC and completely

derived from the machine specification.

• The real time behaviour simulation

represents the process- and time behaviour

of the machine devices for all PLC relevant

processes.

• To generate this simulation the mechanical

and electrical behaviour of the real

machine has to be modelled.

• This behaviour model describes the

dynamic processes of sensors, actuators

and mechanisms within the machine.

Die Virtualized Machine with WinMOD

System

Coupling

WinMOD

Machine Simulation WinMOD 3D

Visualization

SPS

Virtualized Machine – the Structure

or

WinMOD System

Virtualized Machine/Installation

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Virtual machine from virtual components

• For all real devices of the

machine/installation virtualized

components will be created in WinMOD.

• These components contain

the real time behaviour simulation

of the process- and time behaviour of the

machine devices for all PLC relevant

processes.

• With a real time behaviour visualization

the machine mechanisms and movements

can be visualised during the simulation.

• The input- and output connections of the

virtual components are conform to the real

devices.

virtual component

physically correct real time behaviour

real machine component

PLC output signals (e.g. move for- and

backward signals)

PLC input signals (e.g. end positions and

actual piston stroke)

zustandsunabhängige

Ansteuerung möglich

real time movements

and status signals of

the piston

e.g. pneumatic cylinder

Realization

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WinMOD Project from virtual components

specification of

the real used

components

selection of a virtualized component

from a WinMOD component library parameterisation of the

virtualized components at the

actual WinMOD Project

the WinMOD Project

the real component

the virtualized component

• A virtualize machine will be created by

combination and parameterisation of

virtualized components.

• A WinMOD Project can represent a single

machine or a complex plant with many

machines.

• The virtualized components can be archived

in WinMOD component libraries.

• It is possible to generate a WinMOD

Project automatically, if certain

engineering data of a project are available..

• So a WinMOD Project can be created at the

push of a button.

Realization

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Structure of the WinMOD Project

structure of the WinMOD Project

for a virtualized machine

process image

(I/O signal scheme)

Add-On WinMOD Recorder

(online signal recording)

Add-On WinMOD

SIMLINE 3DVisu (3D-visualization)

technology scheme

(process visualisation)

behaviour simulation

(virtualized components)

• The virtualized machine will be created

by combination and parameterisation of


• The process image defines the

communication with the PLC-software.

• The process visualization gives a

schematic view of the whole process

behaviour.

• If 3D-design data are available a 3D-

visualisation of the machine can be

created.

• An integrated WinMOD Recorder can do

time based signal recordings during the

simulation, which can be exported.

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Views of the WinMOD Project

view 1 view 2 view 3

WinMOD Project

free configurable

WinMOD-window schemes

shows:

virtualized components,

technology scheme,

signal recorder

shows:

control components,

technology scheme,

I/O signal scheme

shows:

virtualized components,

IO-signal scheme

• The WinMOD Project consists of several

WinMOD Simulation windows which

contain the simulation elements e.g. the


• These windows can be arranged in the

project windows according to the use

cases.

• Each simulation window can have it‘s own

size and zoom.

• The window arrangements can be saved

as WinMOD window schemes.

• Always the best user interface for every

use case in the WinMOD simulation.

All at a glance

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• The virtualized machine/installation

replaces the real machine/installation.

• The virtualized machine can be connected

to the real automation system with

different field bus systems.

• Best quality insurance through separation

of software developer at programming

device and independent commissioner at

the WinMOD Project.

• Transparent software test with third

persons (constructing engineers,

operators,…).

• test cases for disturbance reaction

• test cases for the handling of HMI-system

WinMOD Project

Use for Virtual Commissioning

3D-visualisation commissioner sw-developer

real

automation system

fieldbus

HMI

PLC

Real Automation System with

Virtualized Machine

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better teamwork for all concerned parties

• Avoiding of misunderstandings at the

specification, process behaviour and

handling.

• Optimization of processes and

disturbance reaction through

parameterisation of the real time simulation

components.

• Transparent process behaviour through

real time 2D/ 3D-visualization of the

whole machine/installation.

• Time based real time signal recording

with the signal recorder for behaviour

analysis.

WinMOD

SIMLINE 3DVisu

WinMOD Recorder

Use for functional planning

WinMOD Project virtualized PLC

electricity

mechanics

software planning team

WinMOD Visualisation

Planing Project

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• Training of the operating personnel

before the start-up of a new machine/

installation.

• Easy location- and status detection

of machine components within

the 3D visualization.

• Training of hard incident scenarios

which would destroy the real machine/

installation.

• briefing of new personnel

• The 3D visualization gives more

transparency of process- and training

activities to the operating personnel.

Use for education and training

real

automation system

HMI

PLC

WinMOD project with incident scenarios

and extended 3D-visualisation

trainees

trainer

Training Project

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Use for service and optimization

• Individual use for the incident analysis

and for the preparation of service

activities.

• Implementation of time-consuming

process optimisations without the real

machine - just at the office.

• Analysis of critical operating states

without endangering of the real machine/

installation.

• Factory management through location

identification of machines and devices

within the 3D visualization at certain

service situations.

1

3

operating

personnel

service

personnel

real machine

in the production

virtualized machine

in the office

real

automation

system

real

automation

system

need of optimisation

or error correction time-consumpting

customising and

critical testing installing of the

customisations

2

WinMOD Service Project

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With WinMOD you can simulate machine/installation behaviour and edit

signal lists.

specification and

functional description

quality management

software test and

qualification

commissioning

training and presentation

service and support

WinMOD supports the quality management with continuous software tests

according to the development status.

Through a transparent technology-oriented test environment it is possible to

organise joint software test sessions with customer and contractor.

A step-by-step commissioning and test run can be supported with the

combination of simulation and real machine. The WinMOD Recorder can

record signals event-driven to compare the behaviours.

Through the combination of WinMOD with the automation system arises the

virtualized machine. This allows training of operating personnel before the

commissioning of the real machine/installation.

The machine/installation is in the production. With the simulation you can

check and correct known errors without downtime. Changes within the

software can be tested without the real machine.

Summary

Documents

Real-Time Simulation Center for Automation Technology… · WinMOD_for_Manufacturing Technology_en.ppt ... • Transparent process behaviour through real time 2D/ 3D-visualizationWinMOD