b07 - Process Simulate Virtual Commissioning PDF

Process Simulate Virtual
Commissioning
Shay Shomroni
Director Industry Solutions

Manufacturing Business Group
shay.shomroni@siemens.com
© 2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Tool
Shop-floor challenges change
procedure
Conveyor
Throughput optimization
reaction
Sensor
positioning
Electrical
device
signals
Handling
variants
Safety
procedures HMI synch
with tools
Page 2 Siemens PLM Software
Virtual Commissioning
Environment for testing, simulation and debug of PLC programs, HMI

code, and automation scheme with a virtual model of a factory
Faster
• Shorter time to production
• Quicker change cycle
Better
• High quality PLC code
• Optimized performance
Less Expensive
• Cost of production stop
• Cost of prototype parts
Story board
OEM XYZ Supplier 123
+
Supplier Analyze: What is required?
Tooling
Clamps and Pose sensors address
new variant
Robotics
OEM Standard program considers
pedestal gun and new variant
Control
HMI test for clamps, safety procedures
and E-Stop pass
EBZ Case Study
https://sales.industrysoftware.automation.siemens.com/accesscount/188
28/EBZ-Group-Customer-Testimonial-R7T1A1
Primary Line Builder Challenge
Validate OEM changes faster and more accurately
Tooling Tasks
Adaptation of Process, based on existing design

 Define clamp functionality and specific behaviour
 Mapping to PLC Signals and dynamic testing
Change the existing Process to multi variant

 Correct Material Flow
 Variant Detection
 Mapping to PLC Signals and
dynamic testing
Tool design Example
OEM instructions
OEM XYZ Supplier 123
The Use Case: Requirements
Peripheral Resources
Safety
Variants
Synchronization
Native Language
OEM Standards
Maintenance
Traditional Work cell Simulation
Robotics engineers tasks
Manage changes after receiving a new path:

 Variant Branching
 Synchronize robots to PLC
 OEM Standard Robot Code
 Download programs and test
Robotic Simulation
Event-Based Simulation
 Realistic cycle time

 Conveyor control (physical, logics)
 Material handling between stations
 Load, steady state, variants and shutdown
scenarios
Time based
OP 1
OP 2
Event-based
OP 1 OP 3
A OP 2
NOT A OP 3
Supplier Analyze: What is required?
Tooling
Clamps and Pose sensors address
new variant
Robotics
OEM Standard program considers
pedestal gun and new variant
Control – virtual commissioning
Mechanical Electrical
 Kinematics  Inputs / Outputs

 Robot Programs  Logic
 Mechanical Sequences  Interlocks
 Layout  HMI
 Clearances  Diagnostics
 Cycle Time  Safety
Evaluate Mechanical and Automation System behavior

Virtual Commissioning
 Easily create a realistic shadow of a production

environment
 Test & Debug PLC code
 Long before the real system is build
 Minimize impact on existing environment
 Use real PLC H/W or emulated S/W
Start of
Production
Test earlier Don‘t disturb

production
VC Environment
Process Digital Process Automation

Knowledge Design Validation
Simulation
Real Time
Signal Signal
Mapping Exchange
OPC (Client & Server)
Controls
PLC Code
PLC HMI
Virtual Commissioning Demo
Life Cycle Processes
(Current State)
Estimating Planning Design Construction
Process Planning & Documentation
Controls Design
Workcell Simulation
Equipment Design
Program
Installation Debug Try-Out
Robots
Cost and Time
Life Cycle Processes
(Future State)
Process Planning & Documentation
Controls Design Debug
Workcell Simulation OLP

(Enhanced) (Enhanced)
Equipment Design
Installation Debug Try-Out

(Physical)
Cost and Time
AMT Testemonial
https://sales.industrysoftware.automation.siemens.com/accesscount/24847/Virt
ual-Commissioning-Video-AMT-Testimonials-R7T4N3
Benefits
 Earlier
start of production
OEM
 Lower cost on changes
 Major Riskreduction:
Tier 1 Mature processes
Primary LB Right the first time
Standardization of processes and components
Tier 2  Collaborative and Efficient Engineering

Eng Houses Validation reduces risks on site
Process Simulate Take Aways
 Highly functional & easy to use

 Widely deployed by OEMs and LB
 Natural upgrade of Robcad
 Connected to TC backbone
 Proven value and customer benefits
THANK YOU!

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Process Simulate Virtual

Director Industry Solutions

Environment for testing, simulation and debug of PLC programs, HMI

OEM XYZ Supplier 123

Validate OEM changes faster and more accurately

Adaptation of Process, based on existing design

Change the existing Process to multi variant

OEM XYZ Supplier 123

Traditional Work cell Simulation

Manage changes after receiving a new path:

 Realistic cycle time

 Kinematics  Inputs / Outputs

Evaluate Mechanical and Automation System behavior

 Easily create a realistic shadow of a production

Test earlier Don‘t disturb

Process Digital Process Automation

Estimating Planning Design Construction

Process Planning & Documentation

Cost and Time

Estimating Planning Design Construction

Process Planning & Documentation

Controls Design Debug

Workcell Simulation OLP

Installation Debug Try-Out

Cost and Time

Estimating Planning Design Construction

Tier 2  Collaborative and Efficient Engineering

 Highly functional & easy to use

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