From mechanical design and controls programming to validation and virtual commissioning – machine and plant builders have discovered many ways that simulation can help minimize development risk. Those benefits multiply if the simulations can easily be adapted and reused in future projects. That's exactly the promise of a new solution from B&R and ISG.

The new solution from ISG and B&R offers three levels of automation for configuring simulation scenarios – manual, template-based or completely automated.
  • Key requirements of a simulation:
  • Test the control application – just like on a real machine, without any new programming
  • Test the whole system – including intelligent fieldbus components, functional safety and real production data
  • Test "what-if" scenarios – what happens if a sensor fails suddenly or missing parts are identified
  • Run as a digital twin – for continued process optimization during ramp-up and operation
  • Provide a library of simulation models – to match the modular structure of the machine

Complete platform

A look at the requirements reveals that the value a machine builder gets from a digital twin is closely tied to how accurately it matches its physical counterpart. ISG and B&R have co-developed a simulation solution that meets all these requirements while at the same time offering the flexibility to be used in a variety of applications. It's based on the ISG-virtuos simulation platform. "We've created a complete simulation platform able to handle a wide variety of applications," says Christian Daniel, business manager for simulation technology at ISG.

The real controller can be connected to the simulation platform via TCP/IP or in real time via POWERLINK. Either way, communication originates from the application project in B&R's Automation Studio engineering environment, so developers can perform virtual commissioning using the existing control application without any new programming.

The simulation platform and real controller can be connected either via TCP/IP or real-time POWERLINK.

Build your own scenario

The ISG-B&R simulation solution also lets developers quickly configure simulation scenarios from a library of modular components. They can create a set of components that matches the modular structure of a packaging line, for example. "You don't get the full benefit of an investment in simulation if you have to redo all the groundwork for each new project," knows Daniel. "It's much better if you're able to create an assembly kit of modular components you can draw from again and again."

Simulation scenarios are created for each unique application by assembling a variety of virtual devices, assemblies and systems. Each virtual component is an exact representation of its physical counterpart – from parameters and interfaces to control behavior. "Developers can create a library of virtual components that accurately model the mechatronic behavior of their modular machine components," says Daniel. "Machine builders then use these virtual components to generate custom configurations."

Templates and reusable components save time

The new solution from ISG and B&R offers three levels of automation for configuring simulation scenarios – manual, template-based or completely automated. "What's really special about the solution," explains Daniel, "is that you can conduct reproducible system tests including POWERLINK with perfectly accurate timing behavior and build simulation scenarios from a library of reusable virtual components."

To get meaningful results, the control system must be tested in conjunction with fieldbus components and put into operation in the context of a full system test. "With the complete simulation solution from B&R and ISG, that's exactly what is possible," says Daniel. "It ticks all the boxes for what a perfect tool should do and offers machine builders maximum return on their investment in simulation."

Christian Daniel

Business Manager - Simulation Technology, ISG Industrielle Steuerungstechnik GmbH

"Developers can create a library of virtual components that accurately model the mechatronic behavior of their modular machine components."

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