Virtual Development/Commissioning

Introduction

Contemporary automation technology confronts the problem of creating ever intricate systems with greater efficiency and speed. Virtual development and virtual commissioning have become essential technologies that enhance development processes and minimise expenses. Through the utilisation of simulations and digital twins, organisations can identify faults at an early stage—prior to the construction of real prototypes. This results in a significant decrease in time-to-market while enhancing system quality and reliability. The primary inquiry is: What precisely are virtual development and virtual commissioning, and in what manner do these technologies impact the industrial development process? This article examines fundamental principles, benefits, problems, and the influence on the overall manufacturing workflow.

What Is Virtual Development?

Definition and Core Concepts

Virtual development entails the utilisation of digital models, simulations, and software tools to create, evaluate, and enhance automated processes and systems within a virtual environment prior to the construction or implementation of any real systems. This facilitates the simulation of machinery and plant operations under realistic conditions, enabling the early detection of problems.

Objectives in Automation Technology

The principal objective of virtual development is to enhance efficiency, expedite time-to-market, and diminish costs by obviating the necessity for physical prototypes and testing configurations. It facilitates early mistake identification, system optimisation, and enhances collaboration among engineering disciplines.

Advantages Over Traditional Physical Development

• Cost reduction by minimizing the need for physical prototypes
• Time savings through faster testing and adaptation
• Error reduction due to early problem identification
• Flexibility in changes and adjustments without physical interventions
• System optimization before actual commissioning

Tools and Software for Virtual Development

Prevalent instruments encompass CAD systems for modelling components and plants, simulation software such as MATLAB and Simulink for system behaviour analysis, and digital twins, which are virtual representations of physical systems that provide real-time monitoring and optimisation. Moreover, PLC programming and simulation software such as TIA Portal or Codesys is utilised to evaluate control logic prior to actual implementation.

What Is Virtual Commissioning?

Definition and Purpose

Virtual commissioning entails the testing and implementation of automation systems and controls within a simulated environment prior to their application on physical machinery or facilities. The objective is to validate system functionality, identify problems, and enhance performance to guarantee seamless integration into actual production environments.

Differences Between Physical and Virtual Commissioning

Physical commissioning transpires in the actual environment, with control systems directly interfaced with hardware. Conversely, virtual commissioning use digital models and simulations to evaluate systems without the necessity of real apparatus. Physical commissioning is susceptible to unexpected faults, but virtual commissioning offers a regulated setting for diagnostics and optimisation.

Advantages of Virtual Commissioning

• Error detection: Identify issues early, before they affect production
• Early testing: Validate all functions and processes in a simulated environment, making real commissioning faster and more efficient
• Cost savings: Reduce the need for physical prototypes and trial runs, lowering material, labor, and time expenses

Example Software Solutions

• Siemens SIMIT: Offers realistic simulation of automation systems to support virtual commissioning of control systems
• Beckhoff TwinCAT: Integrated automation software that includes features for simulating control logic in advance
• Rockwell Studio 5000: Automation software capable of virtual commissioning and performance testing in simulated environments

Benefits of Virtual Development and Commissioning

Cost Reduction

By remotely commissioning systems, one can circumvent expensive errors, delays, and the necessity for physical testing. Problems that would incur significant costs during physical commissioning can be resolved in advance, thereby reducing rework and modifications.

Time Savings

Virtual models provide immediate simulations and expedited alterations, markedly decreasing development and commissioning durations, hence accelerating project execution.

Early Error Detection

Deficiencies in control logic, mechanics, and electrical systems can be detected in the virtual phase prior to affecting physical commissioning—enhancing troubleshooting efficacy and mitigating production hazards.

Production Process Optimization

Virtual commissioning facilitates meticulous planning and assessment, permitting optimisation prior to actual implementation. This guarantees enhanced alignment of all system components and augments operating efficiency.

Integration of Virtual Development and Commissioning

Collaboration Between Development and Commissioning

Virtual development and virtual commissioning synergistically enhance collaboration across all stages of the engineering process. Virtual development facilitates planning and design, whereas virtual commissioning replicates real-world implementation. This mitigates transition challenges and guarantees the cohesive integration of all components prior to production.

Use of Digital Twins

Digital twins are virtual representations of machines, plants, and controllers utilised in virtual development and commissioning. They faithfully emulate real-world environments and provide a dependable foundation for testing and optimisation. Engineers can implement real-time modifications based on simulations prior to deploying physical hardware.

Interactive Simulations

Interactive real-time simulations facilitate the evaluation of machinery and plant performance under authentic conditions. These simulations offer comprehensive system dynamics analysis, facilitating the discovery and resolution of problems without the need for physical testing.

Challenges of Virtual Development and Commissioning

Complexity and Accuracy

Ensuring that virtual models adequately represent the real world is a significant task. High-quality simulations must account for all pertinent elements of actual machinery and systems. Modelling inaccuracies can result in incongruent outcomes, diminishing the efficacy of virtual testing.

Integration with Existing Systems

Integrating virtual models with actual hardware presents an additional hurdle. Effortless interaction between virtual and physical systems necessitates clearly specified interfaces and protocols. Tailored solutions are frequently required to guarantee that virtual commissioning effectively regulates and supervises actual equipment.

Expertise and Training

Effective virtual commissioning necessitates profound expertise. Engineers require expertise in simulation technologies and a comprehensive understanding of actual system dynamics. Training and ongoing education are essential to maximise the possibilities of virtual development and commissioning.

Future of Virtual Development and Commissioning

Integration of AI and Machine Learning

Artificial Intelligence (AI) and Machine Learning (ML) are revolutionising virtual testing and simulations. AI systems can find trends and abnormalities in simulation data to uncover possible faults or optimisation opportunities. Machine learning models enhance behavioural prediction in various settings, facilitating more realistic simulations.

Augmented Reality (AR) and Virtual Reality (VR)

Augmented Reality (AR) and Virtual Reality (VR) provide robust visualisation and interaction functionalities. Augmented reality superimposes virtual information onto physical devices, facilitating real-time engagement. Virtual reality offers a completely immersive three-dimensional environment that enables engineers to investigate and simulate systems, hence improving planning and debugging processes.

Automation of Virtual Commissioning

As technology progresses, virtual commissioning is becoming further automated. Automation tools and AI-driven systems facilitate efficient commissioning with limited manual intervention, hence decreasing time, minimising human error, and enhancing consistency and quality.

How Xentara Supports Virtual Development and Commissioning

• Integration of virtual models with real control systems: Xentara facilitates the amalgamation of digital twins with existing control systems, enabling testing and simulation without the necessity of physical hardware.
• Real-time simulation and testing: Xentara facilitates real-time simulation of automation solutions, enabling early detection and rectification of errors—thereby diminishing dependence on physical prototypes.
• Connection of Soft-PLCs, classic PLCs, and virtual controllers: Xentara facilitates uninterrupted communication among various control systems, promoting virtual commissioning across a range of hardware and software.
• Scalable and flexible automation architecture: Xentara is appropriate for both straightforward and intricate systems, enabling comprehensive infrastructure modelling and optimisation before actual deployment.
• Support for IT and AI applications: Xentara incorporates machine learning and artificial intelligence in virtual commissioning to improve system performance and facilitate predictive maintenance and diagnostics.

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Conclusion

Virtual development and commissioning are essential for optimising automation operations. Utilising digital twins, simulations, and contemporary software, organisations can improve efficiency, decrease expenses, and expedite time-to-market. Proactive error identification mitigates expensive rework and delays, enhancing the quality and dependability of final systems.

The two techniques synergise through their close integration, facilitating seamless collaboration among engineering specialities. Digital twins and interactive simulations are essential for evaluating and validating system performance in real-world scenarios.

Notwithstanding its advantages, obstacles persist—particularly about model correctness, connection with current systems, and the want for proficient workers. Nonetheless, with breakthroughs in artificial intelligence, augmented reality, and automation, these procedures are swiftly developing and becoming increasingly sophisticated.

Companies such as Xentara offer robust support by facilitating the connection of virtual models with actual control systems, providing real-time simulation capabilities, and supplying a scalable automation platform. These advances facilitate the optimisation and automation of the whole development and production process, enhancing efficiency and minimising errors.

Ultimately, virtual development and commissioning are revolutionising automation and establishing a foundation for an agile, cost-effective, and future-ready industry capable of swiftly responding to market demands.