Virtual Manufacturing Solutions

Lee Van EverySenior Account Executive

CENIT North America

Industry 4.0 – The Next Revolution?

• What is Industry 4.0?

• Interoperability - Equipment, Human Communication through Sensor

Connections

• Information Transparency – Sensor Data allows Virtual response to real world

information, 3D Digital Components to behave as Real Components

• IoT – Internet of Things concept is the Core

• Digital “Smart” Factory – Agile Virtual Environment, Digital Twin

Advanced Manufacturing, Paradigm Shift?

Wikipedia

Industry 4.0 – Next Industrial Revolution

Digital Factory

Industry 4.0 - Components

• What elements comprise the next Industrial Revolution?

• Many of these components are in use today• 3D Mechanical Design & Planning• Autonomous Robots• Simulation• The Cloud• System Integration• Cyber-Security - Ultra important for Industry 4.0

• Internet of Things• Largely inter-networking between physical equipment

allowing the storage and exchange of data• 1982 Coke Machine! 1st example Wikipedia

3D Simulation Software: Key Component

• 3D Initial Concept – User Friendly, CAD components should mimic real world components (Conveyors, Controllers, Robot Arms)

• Validate Concept – Reach study, Virtual Teach Programs or CAD-To-Path Technology, Signalling

• 3D Simulation of Concept

• Generate True PLC / Robotic programs

3D Concept - Make Life Easier

• Fast Cell Layout – Drag & Drop

• Mechanical & Electrical Connections – Mimic shop floor

• Immediate Reach / Validation Study

• Simulation w/ all active components

• High End Rendering

3D CAD Components

• CAD Resources - Usability• Behave Correctly

• Intuitive

• Easy to Adjust (kinematics, velocity for cycle times)

• Smart Connections

• Cable Dressing

• Import CAD formats

• AML – Automation ML – reserve kinematics

• On/Off Signal Calls – simple parameter

Today’s Engineering Process

Simulation Based Engineering Process

3D Concept Validation

• Targets

Create simple robot motion programs, using the 3D simulation model to verify feasibility, reachability and cycle time

• Tool path teach

• Collision check

• Rough cycle time prediction

• Purpose

Define simulation layout and manufacturing process, which will meet the planning premises.

• Layout space

• Costs

• Production volume

3D Concept Validation – cont’d

• Internal standard motion planner

• Internal standard robot control

• OPC-UA – Open Platform Communication

• What is required to achieve targets?

• Reachability check

• Programming of positions

• Collision check

• Cycle time analysis

• How to achieve this?

Viewer

Kernel

OPC-UA

Solver

Logic

Mechanics

Dynynics

Material flow

Collision

Shares MemoryShares Memory

SimuCtrl.

SimuPLC Ctrl

Simulation Concept - Infrastructure

Fieldbus

Viewer

Kernel

Shares Memory

OPC-UA

Solver

Logic

Mechanics

Dynanics

Mat. Flow

Collision

Shares Memory

Shares Memory

External

OPC-UA

Resource & Layout Builder

Automation ML

Physical Behavior

I/O Signals

Adapter

KInematics

3D Geometry

Logic Behavior

real time External

Automation-ML

External virtual time

Simulation viewing

Behavior solving

Internal motion planningInternal logic

External motion planningExternal logic

Robot Offline Program Validation• TargetsCreation of robot programs, which will not require re-teaching on the shop floor

• collision free

• energy optimized

• cycle time optimized

• PurposeCreate robot programs, using the 3D simulation model to verify the quality of the toolpath and validate the programs

• tool path

• signal communication

Robot Offline Program Validation cont’d

Kernel Control specific robot behavior models

Connection to virtual robot controls (SIL)

Signal communication in virtual-time

Peripheral resources with kinematic and simple behavior models

What is required to achieve

targets? Accurate robot behavior

configuration-, turn handling, …

Accurate motion planner

Signal communication

with peripheral resources (i.e. clamps)

between robots

How to achieve?

Viewer

OPC-UA

Solver

Logic

Mechanics

Dynynics

Material flow

Collision

Shares MemoryShares Memory

External

OPC-UA

PLC Program Validation• Targets• Understand required functionality

• Test the functionalities during development process

• Increase software quality before commissioning phase

• Reduce time of virtual commissioning

• Purpose

Create the PLC programs, using the 3D simulation model to communicate the required functionality and to validate the programs

• Logic programs

• Safety programs

PLC Program Validation

Simulation model with simple behavior model for all actors

Simulation model directly connected to Soft-PLC or alternatively to real PLC

What is necessary to achieve

targets? Signal communication in virtual-time

Structure, functionality and behavior of simulation model identical to real production equipment

How to achieve?

External

OPC-UA

Kernel

Viewer

OPC-UA

Solver

Logic

Mechanics

Dynynics

Mat. Flow

Collision

Shares Memory

Shares Memory

Virtual Commissioning

• Targets

• Test complete functionality

• Find out and fix malfunctions

• Increase software quality

• Reduce risk for commissioning

• Reduce effort for following service phase

• Purpose

Virtual factory acceptance test to validate all real controls, connected to the 3D simulation model instead to the real production equipment.

• Robot and CNC programs

• PLC logic and safety programs

Virtual Commissioning

• How to achieve?

• Simulation model with physical behavior model for all actors

• Simulation model directly connected to fieldbus, for real time communication

• What is required to achieve targets?

• Signal communication in real-time

• Connection of hardware controls (HIL)

• Structure, functionality and behavior of simulation model identical to real production equipment

Virtual Commissioning

Viewer

Real

Kernel

Shares Memory

OPC-UA

Solver

Logic

Mechanics

Dynynics

Material flow

Collision

Shares MemoryShares Memory

Real Time

Fieldbus

In order for Virtual Commissioning

to work, the virtual 3D components

must react to the true PLC programs,

the identical way that real components

would react

Challenges

• Data Security – More Access Points

• Proprietary Production Knowledge – IT Security Risk

• Need for High Degree of Stability to sustain Cyber-Physical Communication

• Difficult to maintain integrity of production process w/ less human oversight

• Resistance – perception of job loss

• Lack of Experience and Manpower overall to implement such highly advanced process Forbes Magazine

Overall Benefits

• Flexible Automation – Production Complexity can be Handled

• Potentially Safer with less Human interaction in cells

• Better control of supply chains with data at every level of the process

• Time – Faster Time to Production with Virtual Commissioning

• Self Correcting Smart Cells

• Industry 4.0 = Connectivity between equipment and the “digital twin”, which allows for greater overall productivity. This directly translates to time and cost savings.

Forbes Magazine

Thank You

Lee Van EverySenior Account Executive

CENIT North America691 N. Squirrel

Address 2

Auburn Hills, MI,

USA

Telephone: 248 309 3243

Email: L.VanEvery@cenit.com

www.FASTSuite.com