VIRTUAL COMMISSIONING - ENTRY TO MODEL-BASED DESIGN & SPRINGBOARD TO SMART INDUSTRY

The current part two of the article carries forward the explanation of why model-based engineering is a step closer to efficient engineering

- Philip HF Wallner & R Vijayalayan

To prepare for the implementation, the models are provided with the data types that will later be used on the PLC. This can also be done largely automatically with tools such as fixed-point designer. After refinement and optimisation to the required accuracy, code can then be generated. However, this is not necessarily written immediately to a controller, but for example in a Dynamic Linked Library (DLL).

This can then be run on a PC or other computer hardware and tested in interaction with the plant model or physical plant. In this way, the functionality of the machine and software can be extensively tested and verified step by step before any hardware is even ready.

Errors are thus found and eliminated early in the development process, and subsequent integration is faster and smoother. In addition, scenarios can be tested that would not be possible on the real machine for safety reasons or because of the risk of damage. Various suppliers, such as Siemens, Beckhoff or Rexroth, also enable the simulation of the complete PLC on computer hardware as an intermediate step.

FROM DEVELOPMENT SEAMLESSLY TO OPERATION

If machine and plant builders follow the paradigm of model-based development, virtual commissioning no longer takes place at a specific point but, like testing and verification, continuously with each intermediate step. They can therefore approach the physical machine with confidence that it will function as desired.

However, the benefits of the models built up along the way are by no means exhausted. They play a central role in the intended smart industry in the further life cycle of machines and plants. They can serve as digital twins of plants in operation and allow both operators and manufacturers to continuously monitor the actual condition of plants.