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Lundström, Viktoria. "Virtual Commissioning : Virtual Commissioning of ABB Production cell." Thesis, Umeå universitet, Institutionen för tillämpad fysik och elektronik, 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:umu:diva-122854.
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The background of the concept, ABB Production Cell, meets the increasing demands from manufacturing industries throughout the world to simplify through standardization and by that reduce investment cost and operating cost throughout the entire lifecycle of the production cell. ABB is delivering the production cell as one easy to order, use, and maintain. The production cell is developed for virtual versions and full scale production cells. The different modules shall be utilized and presented in RobotStudio and configured in Automation Builder. With generic templates and hardware it provides e.g. early visualization, standardized systems, shortened design/development phase, and enable virtual FAT(Factory Acceptance Test). There is multiple ways of doing a virtual commissioning and it’s a known approach for testing software and hardware together. The method used in this project is known as SIL (Software-In-The-Loop). This means that the hardware runs as software- e.g. PLC, Drives and HMI- with same properties and behavior as the real hardware. This thesis focus on describing phases of an automation system and see how different phases are affected by a virtual commissioning. Benefits will be described and the existing software will be evaluated. Furthermore, an attempt of virtual commissioning has been done with focus on connecting the software for stable communication with the virtual PLC and make a PLC-task with a handshake to the robot controller and the virtual environment. The system is tested in a virtual environment with vFAT and then on the workshop (FAT). This was done to see if the softwares replicated the same behavior as the hardwares. The result for the virtual commissioning is that it is possible to run the virtual PLC (VAC500) with the same time interface, behavior, and signals as the real PLC (AC500).Bakgrunden till konceptet ABB Produktions Cell är ökad efterfrågan av ett enkelt sätt, genom standardisering, att reducera kostnaderna för hela livscykeln för en produktions cell. ABB Produktions cell ska vara enkel att köpa, använda och upprätthålla. Konceptet är utvecklat för att kunna skapa fullskaliga modeller av produktionsceller. Utrustningen och den virtuella miljön finns i RobotStudio och konfigurationen av HMI,Drives och PLC i AutomationBuilder. Generiska mallar, mjukvaror, hårdvaror ger möjlighet för t.ex. tidig visualisering, förkortad design och utvecklingsfas, standardiserade system samt tidig verifiering och test genom virtuell FAT(Factory Acceptance Test) Idrifttagning av ett automationssystem kan tillämpas både virtuellt och traditionellt. Det finns flera olika metoder för virtuell idrifttagning och metoden för detta projekt är SIL(Software-In-the-Loop). Detta går ut på att hårdvaror såsom HMI, PLC och Drives körs som mjukvaror, med samma beteende och egenskaper(tidsgränssnitt) som de riktiga hårdvarorna. Den här uppsatsen fokuserar på att beskriva de olika delarna av ett automationsprojekt och hur de påverkas av virtuell idrifttagning. Fördelar med metoden tas fram och den befintliga utrustningen utvärderas. Ett försök till virtuell idrifttagning har genomförts där fokus varit att skapa en sekvenskod för logiken till en befintlig produktionscell samt skapa kopplingar mellan mjukvarorna. Detta testas och verifieras först i virtuell miljö med virtuell FAT(Factory Acceptance Test) och därefter har den verkliga produktionscellen verifierats i verkstaden(FAT). Utvärdering om beteende och cykeltider har också gjorts för att dra slutsatsen om vFAT kan jämföras med FAT under utvecklingsstadiet. Resultatet för den virtuella idrifttagningen är att det är möjligt att köra virtuell PLC(VAC500) med samma tidsinterface, beteende och signaler som den riktiga PLC(AC500).
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Almansa, Fernández Jesús Tomás, and Maqueda Juan Pablo Vargas. "Virtual commissioning with virtual reality." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-18574.
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The industry is nowadays going through a transformation in networking technologies which leads to what it is called Industry 4.0. This stage of the industry is arriving from the hand of the internet of things. Having connected all the elements within a factory allows to control and keep track of them telematically. Virtual commissioning is in charge of designing, testing and debugging the system before it is even built. This project tries to approach virtual reality to virtual commissioning and create the virtual model of a human in these simulated environments. Technology allows introducing human interaction for many purposes such as operator training. To do this project properly a methodology will be followed for the design and creation. Once the background, frame of reference and literature review are established, the development can start. The development of the project has taken place alongside Simumatik Open Emulation Platform, consisting of creating the body of a person, as simple as possible, following ergonomics, into this platform for commissioning purposes. The model will be able to interact with the virtual environment like robots, boxes, and sensors. To sum up, the complexity of the model will be limited to the inputs coming from the head and the hands. There exist infinite solutions for which position should be the rest of the body, therefore, this project aims to fix some variables to find valid solutions. Finally, the project achieved building a digital human model in which the main goal was building the arms that are estimated. The model is capable of interact with Simumatik´s environment that has been created specifically to show the functionalities of this project, being detected for sensors and robots of the system.
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Steen, Patrik. "PLC&Virtual Commissioning : En studie i verifiering av PLC-logik genom Virtual Commissioning." Thesis, Karlstads universitet, Fakulteten för hälsa, natur- och teknikvetenskap (from 2013), 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kau:diva-69379.
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PLC kan idag vara det mest använda styrsystemet till industriella applikationer. Verifikation av programmerad PLC-logik är av stort värde och kan göras på olika sätt. ÅF Karlstad vill idag börja se över möjligheter till implementering av Virtual Commissioning som ett alternativ till minskning av ledtider. I det stora hela blev målet för detta projektarbete att i Xcelgo Experior bygga upp en 3D-miljö som liknar en saltvatten-process på Barilla i Filipstad, skriva PLC-logiken i Siemens TIA-portalen och testköra logiken i 3D-miljön. Och av detta kunna ge underlag till eventuella investeringar i denna teknik för ÅF Karlstad. Gränssnittet Xcelgo Experior visade sig var funktionellt och lättarbetat. Dock hann inte programutvecklarna få i stånd den uppdatering av modulkatologen som krävts för att tillräckligt kunna efterlikna Barillas process att det försvarbart skulle kunna verifiera PLC-logiken. Efter överläggande med min handledare på ÅF, Anders Emanuelsson, bestämdes att i stället verifiera logiken visuellt i Siemens HMI. Då detta projektarbete endast delvis kommer uppfylla de syften och mål som satts kommer istället en verifiering av PLC-logiken för processen att utgöras av Siemens HMI. Dock har användandet och testkörning av mindre skriven kod, anpassat för nuvarande version av Xcelgo, givit en bild av möjligheterna att effektivt validera PLC-logik då en version lämpad mer för den Värmländska industrin kommit.
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Hoffman, Peter. "On virtual commissioning of manufacturing systems." Thesis, University of South Wales, 2016. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.735542.
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Binnberg, Dennis, and Viktor Johansson. "Virtual Commissioning : Emulation of a production cell." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-12999.
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Volvo is continually updating and replacing their equipment and want to investigate the possibility to shorten the time it takes to implement changes and shorten the time in commissioning projects. The use of an emulation model of a production cell can shorten the commissioning time since the equipment and sequence of the cell can be thoroughly tested before implementation. Volvo also wants to investigate the possibility to validate equipment using emulation. The main objectives are to find an emulation software that suits Volvo’s needs and build an emulation model of an actual production cell at Volvo called G750. A literature review was performed in which the authors gained knowledge about virtual commissioning, simulation and emulation and the usage of these. A market survey was conducted in order to find emulation software that could handle Volvo’s complex production equipment consisting of ABB robots and Siemens PLC. A method for building emulation models of existing production equipment was found during the literature review. The software used to build the emulation model was Simumatik3D. Other software used to make the model as realistic as possible includes RobotStudio, WinCC and PLCSIM. The emulation model handles approximately 350 inputs and outputs. When the emulation model was finished experiments were conducted in order to answer research questions and to reach the main objectives. The experiments validate that the emulation model is representative of the real production cell regarding programming, fail scenarios and movement.
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Vico, Arjona Francisco, and Torregrosa Daniel Pérez. "Development of synthetic cameras for virtual commissioning." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-18576.
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Nowadays, virtual commissioning has become an incredibly useful technology which has raised its importance hugely in the latest years. Creating virtual automated systems, as similar to reality as possible, to test their behaviour has become into a great tool for avoiding waste of time and cost in the real commissioning stage of any manufacturing system. Currently, lots of virtual automated systems are controlled by different vision tools, however, these tools are not integrated in most of emulation platforms, so it precludes testing the performance of numerous virtual systems. This thesis intends to give a solution to this limitation that nowadays exists for virtual commissioning. The main goal is the creation of a synthetic camera that allows to obtain different types of images inside any virtual automated system in the same way it would have been obtained in a real system. Subsequently, a virtual demonstrator of a robotic cell controlled by computer vision is developed to show the immense opportunities that synthetic camera can open for testing vision systems.
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Biggi, Pierfrancesco. "Virtual commissioning di un'isola robotizzata per pallettizzazione." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2021.
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Oggigiorno siamo nel contesto storico della quarta rivoluzione industriale, o industria 4.0, la rivoluzione che porterà ad una produzione totalmente automatizzata ed interconnessa.
A fronte di richieste di prodotti sempre più complessi, la simulazione può essere d'aiuto alle aziende che operano nel contesto dell'automazione industriale.
Si parla quindi di Digital Twin e Virtual Commissioning come strumenti utili per testare in maniera predittiva il comportamento di un macchinario tramite simulazione.
Questo lavoro di tesi è stato realizzato durante un tirocinio aziendale. L'obiettivo è stato capire come il Virtual Commissioning potesse essere sfruttato dall'azienda nel lavoro di tutti i giorni.
Si è quindi deciso di mettere in servizio virtuale l'isola di pallettizzazione, una commessa già conclusa il cui comportamento risulta essere ben definito e conosciuto al fine di riprodurlo tramite simulazione.
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García, Concejero Yeray, and del Río Miguel Antonio Salazar. "Emulation of industrial Fieldbus modules for Virtual Commissioning." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-17486.
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The evolution of the industry, known as industry 4.0, has introduced new technologies such as Virtual Commissioning and Industrial Internet of things. Nowadays, virtual models of automated systems are being created in order to be tested while being built in real life, what includes PLC programs, robots, etc. In order to provide a real behaviour emulation, these virtual models should be as similar to reality as possible. Currently, the components communication in a real system is done through Internet with the use of fieldbuses I/O modules. Right now, these modules are not integrated in the virtual model, as the PLC program returns an error due to the hardware not being found. This implies that the PLC project must be modified, and a workaround must be done in order to connect the I/O cards components of the modules. Furthermore, it means that two PLC projects need to be maintained at the same time, one for the real system and another for the virtual system. In this thesis, a research was done to prove if fieldbuses modules could be emulated, helping to improve Virtual Commissioning. The final goal is to allow a PLC project created for a real system to be run again the corresponding virtual model without any change. To achieve this, a driver able to emulate the communication behaviour of an Ethernet/IP fieldbus module is developed and tested against a real PLC program.
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Svantesson, Andreas. "Investigation of Virtual Commissioning for a Small Enterprise." Thesis, Linköpings universitet, Industriell Produktion, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:liu:diva-167457.
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In order to test an automation code for a production cell it is necessary to have access to the physical model. Therefore, the automation code is validated in the end of the design process. Finding and correcting faults in the code takes time and changes late in the design process tend to be expensive. Having a virtual model of a production cell with the same features as a physical model enables to test automation code and evaluate different features in an early stage of development. The process of having a virtual model to validate code and try out new features is called Virtual Commissioning (VC). The ability to detect errors in the code and identify problems early in the process can lower the lead time for the project and reduce the overall cost. Virtual Commissioning is a relative new process step in the industry and have so far mainly used in larger enterprises. This project has been done at a company named NPB Automation AB, located in Jönköping, Sweden. NPB is a smaller company that designs and produces robot cells that are fully automated. This project is an investigate to see if a software that can perform a Virtual Commissioning should be added to their lineup of tools. This task has been managed by empirically finding how a Virtual Commissioning can be set up. To find out how Virtual Commissioning can affect different fields at the company interviews were held with personnel from different working fields. To get practical knowledge and verifying that Virtual Commissioning can be performed on a robot cell produced at the company, a Virtual Commissioning were set up of a subsystem of a robot cell. The Virtual Commissioning in this project was set up with the software Emulate3D connected to a Rockwell PLC model 1769- L33ERMS, the PLC code used were written in Studio 5000 Logix Designer. The conclusion of his project is that Virtual Commissioning can reduce time to market by reducing the commissioning time. The tasks where Virtual Commissioning will benefit the most is in new projects or when validating changes.
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Kuwornu, Delali Korku. "Virtual commissioning of automatic machines: performance evaluation and robotic integration." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2019.
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This thesis pertains to the virtual commissioning process executed for an Automatic machine, the E-contiuous for TELEROBOT to test the Controller Software of the said machine’s Motion controller. It also looks at how this virtual commissioning process and results affected the real machine, while focusing on the benefits of the particular platform used, and its ability to capture all necessary behavior of the real machine model into the virtual one. The process was divided into three main stages and then the model was passed through each stage to obtain the final model which was tested and results posted. Also integration of industrial manipulators into virtual environment mainly for experimental analysis and virtual commissioning was looked at to obtain data on the feasibility of these robots for specific functions. Finally, there was the discussion of the future possibilities of virtual commissioning and what could yet be achieved.
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Manfredini, Fabio. "Virtual Commissioning of an automatic machine for the coffee industry." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2020.
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This thesis focuses on the analysis and implementation of a digital model for the virtual commissioning of an automatic coffee cap machine. The software that allowed the model to be built is IndustrialPhysics. IndustrialPhysics is a simulation tool for the realistic and rapid modeling of mechatronic systems. It supports the conversion of mechanical CAD data into physical models and simulation of material flow processes can be performed in real time.
The first purpose is to import a CAD model into IndustrialPhysics, model it by assigning kinematics and logical properties to the elements and implement a logic that allows to visualize the flow of the product in the machine as in reality. Then the virtual model will be connected to a PLC running the control code of the real automatic machine.
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Kong, Xiangjun. "An approach to open virtual commissioning for component-based automation." Thesis, Loughborough University, 2013. https://dspace.lboro.ac.uk/2134/13572.
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Increasing market demands for highly customised products with shorter time-to-market and at lower prices are forcing manufacturing systems to be built and operated in a more efficient ways. In order to overcome some of the limitations in traditional methods of automation system engineering, this thesis focuses on the creation of a new approach to Virtual Commissioning (VC). In current VC approaches, virtual models are driven by pre-programmed PLC control software. These approaches are still time-consuming and heavily control expertise-reliant as the required programming and debugging activities are mainly performed by control engineers. Another current limitation is that virtual models validated during VC are difficult to reuse due to a lack of tool-independent data models. Therefore, in order to maximise the potential of VC, there is a need for new VC approaches and tools to address these limitations. The main contributions of this research are: (1) to develop a new approach and the related engineering tool functionality for directly deploying PLC control software based on component-based VC models and reusable components; and (2) to build tool-independent common data models for describing component-based virtual automation systems in order to enable data reusability.
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Yacob, Filmon. "Model-Based Virtual Commissioning of a Manufacturing Cell Control System." Thesis, KTH, Industriell produktion, 2013. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-129545.
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One of the preferred options of manufacturing organizations to survive in today’s market is to automate, increase flexibility and configurability of manufacturing lines. Control systems and Programmable Logic Controller (PLC) programming are quintessentially important part of an automation system. However, PLC programming and debugging takes time and is error prone; consequently, there has being a growing need for quick development of PLC programs and inexpensive code verification and validation methods. To meet the needs, this thesis paper presents a method of virtual development of control system for a fully automated manufacturing cell. The cell has two robots and five other machines, which each machine operating modes are modeled in MATLAB environment and PLC code is generated from the developed models. The model and their associated PLC code are verified and validated in virtual environments. Step-by-step development, verification and validation approaches are presented and argued. Results show that few hours of modeling efforts can generate thousands of lines of code; hence this method is expected to significantly reduce time, development efforts and costs associated with verification and validation of PLC code. Keywords: PLC Code Generation, Simulink/Stateflow Model, Verification and Validation, Manufacturing Cell.Ett alternativ som föredras för tillverkning organisationer att överleva i dagens marknad är att automatisera, öka flexibiliteten och konFigurering av tillverkningslinjer. Kontrollsystem och Programmable Logic Controller (PLC) programmering är en grundlägande viktig del av ett automatiseringssystem. Dock tar PLC-programmering och debugging tid och är felbenäget, och därför har det funnits ett växande behov av snabb utveckling av PLC-program, billiga kodverifiering och valideringsmetoder. För att möta behoven, presenterar denna avhandling papper en metod för virtuell utveckling av styrsystem för en helt automatiserad tillverkning cell. Cellen har två robotar och fem andra maskiner, som varje maskin driftlägen modelleras i MATLAB miljö och PLC-kod genereras från de utvecklade modellerna. Modellen och tillhörande PLC-kod verifieras och valideras i virtuella miljöer. Steg-för-steg utveckling, verifiering och validering metoder presenteras och argumenteras. Resultaten visar att några timmars modelleringsinsatser kan generera tusentals rader kod, och därmed förväntas av denna metod att minska tiden, utvecklingsinsatser och kostnader förknippade med verifiering och validering av PLC-kod. Nyckelord: PLC Code Generation, Simulink/ Stateflow Modell, Verifiering och validering, tillverkning Cell
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Zoli, Enrica. "Automation Systems and Simulation Environments: Interoperability Standards for Virtual Commissioning." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2021.
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Nowadays advantages achieved through the application of simulation in machine design workflow are quite evident, but actually, it is not widely applied as expected. One of the main causes of limited usage of Virtual Commissioning by System Integration Companies is the high effort that it requires. In fact, to create a complete simulation of a complex automatic machine it is necessary to model physical and behavioural characteristics of each component that are usually defined through different engineering tools characterized by different specific formats.
This thesis aims to find an interoperability standard that can be used to exchange information between engineering software. The most promising one is AutomationML (AML). It is presented and a particular focus is posed on the implementation and interconnection of AML Components for modelling of automatic systems. Stand-alone and co-simulation frameworks for mechatronic simulation have been modelled through AML and tested using software such as Automation Studio and industrialPhysics. Limitations of commercial tools have been overcome through the implementation of a Python script whose role is to enable the import of AML format in industialPhysics. Two possible solutions to the synchronization issue in case of co-simulation framework are presented considering the pros and the cons of both of them. Finally, it is shown a small example of integration of mechatronic and multiphysics simulation to get a more reliable framework for Virtual Commissioning.
From the analysis performed through this thesis activity is possible to highlight that AutomationML is a powerful standard, potentially it can be used to exchange data between engineering tools, but at today's stage, its integration in commercial software is not sufficient to enable an effective interoperability.
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Ariza, Agudelo Daniel. "Virtual Commissioning di una linea di assemblaggio automatica per sigarette elettroniche." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2019.
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Il progetto di tesi su cui si è lavorato è stato svolto in GIMA TT, grazie alla partnership di Hotminds S.r.l. che ha fornito il software di simulazione IndustrialPhysics, sulla linea automatica HS-ESP per il mercato giapponese, che produce un nuovo prodotto di sigaretta elettronica.
La linea, per rispondere alle richieste dell’acquirente, ha richiesto la collaborazione da parte di altre divisioni interne ad IMA, facilitandone e velocizzandone la sua realizzazione. Questo ha permesso di adottare il know-how
esterno ma, al tempo stesso, di adattare il funzionamento della linea ai diversi tipi di controllori che le divisioni utilizzano.
Lo studio si è basato su una linea automatica già assemblata presente in montaggio e pronta per la consegna, analizzando le parti di macchina coinvolte nel confezionamento del prodotto. Una volta importato l’assieme della linea automatica in IndustrialPhysics dal progetto meccanico di Creo Parametric e ridefinite tutte le parti in movimento, gli attuatori e i sensori, si è potuto procedere al collegamento con i diversi controllori. Effettuato il collegamento, nello stesso modello di simulazione, utilizzando una architettura hardware in the loop, che consente di collegare il modello virtuale al sistema di controllo reale, si è provveduto a verificare il corretto funzionamento della parte di linea interessata.
Il principale scopo del modello virtuale è testare il programma di controllo, prevenendo errori di funzionamento del software della macchina prima che sia effettivamente assemblata: in questo progetto pilota si è partiti da una macchina già pronta anche dal punto di vista del programma di controllo. Lo scopo principale della tesi è stato poter testare le funzionalità degli strumenti di Virtual Commissioning e poter collegare più macchine, gestite da più controllori, ad una stessa simulazione, in previsione di una futura applicazione a macchine non ancora implementate di un software di controllo.
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Arenas, Izquierdo Cristina, and Ortega Marcos Lainez. "Emulation of an AVG : Exploring Virtual Commissioning of Automated Guided Vehicles." Thesis, Universidad de Granada, Spanien, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-18899.
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The manufacturing industry is currently being digitalized to make production more efficient. One of the tools that are being implemented in such industries is Virtual Commissioning (VC). In this context, Jernbro Industries wants to keep up with this trend; they wish to know how feasible it is to perform Virtual Commissioning of their Automated Guided Vehicles (AGV). That said, the project aims to investigate and evaluate the feasibility of building and using a virtual model of an AGV for future Virtual Commissioning. A 3-phase process (characterization, creation and emulation) is used following a design and creation methodology. After studying the frame of reference and literature review of this project, the development takes place. This development, which has been done with the Simumatik Open Emulation Platform, consists of examining each AGV’s component, thinking how its operation can be reproduced, building it, integrating it into the same system. Finally, it will be emulated, using the control program that has been written. Some of the conclusions that have been drawn are that the complexity of this kind of system resides in the physics of the device and the level of detail that wants to be achieved. However, creating the functional and visual part of the components is an achievable task besides it is time-consuming.
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Tamburini, Diego. "Virtual Commissioning of a Logistic Plant using Discrete Event System Simulation Software." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2019.
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Questo progetto di tesi, svolto in collaborazione con l’azienda “Sitma Machinery” di Spilamberto e sviluppato all’interno del laboratorio industriale di ricerca “LIAM LAB”, ha come obiettivo lo sviluppo di un modello di simulazione tramite l’utilizzo di software basato su un motore ad eventi discreti. In particolare sono stati studiati due software: “Plant Simulation” ed un toolbox di “Matlab” chiamato “SimEvents”. E’ stato sviluppato un primo semplice progetto in entrambi gli ambienti di simulazione per valutare e confrontare le caratteristiche e le performance di entrambi i software. Fin da subito Plant Simulation si è rivelato più adatto per il tipo di studio necessario ed inoltre fornisce una maggiore flessibilità nella programmazione. Successivamente è stato studiato e modellato un grande impianto per lo smistamento di pacchi in Plant Simulation. Questo secondo progetto consiste in un case study messo a disposizione da Sitma. L’utilizzo di un modello di simulazione durante le fasi di design dell’impianto è stato un aiuto di fondamentale importanza per l’azienda poiché è stato possibile dimensionare correttamente il layout e verificare se erano presenti eventuali errori di progettazione. Inoltre, grazie al supporto grafico che fornisce un modello di simulazione 3D, è stato possibile verificare il corretto funzionamento del sistema.
In questa tesi verrà introdotto il tema del Virtual Commissioning centrato sulle simulazioni ad eventi discreti. Successivamente verranno analizzate e descritte le specifiche di due progetti di simulazione condotti durante il lavoro di tesi e i successivi risultati ottenuti. Per il secondo progetto di simulazione, non è possibile mostrare l’intero layout dell’impianto visto che si tratta di un progetto reale coperto da vincoli di riservatezza.
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Giudiceandrea, Roberto. "Virtual Commissioning of a crown-caps manufacturing machine through hardware in the loop architecture." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2019.
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Questo progetto di tesi, svolto in collaborazione con l’azienda SACMI S.C. di Imola e sviluppato all’interno del laboratorio industriale di ricerca LIAM Lab, ha come obiettivo la realizzazione di un Digital Twin di una sezione di macchina in fase di costruzione in azienda, attraverso l’ausilio del Software commerciale Virtuos. In particolare, dopo aver studiato le caratteristiche del Software, le possibili configurazioni e le tecnologie di comunicazione con PLC di terze parti, è stata eseguita una modellazione cinematica e logica della macchina. Ottenuto il modello, lo si è messo in comunicazione con il codice di controllo fornito dall’azienda. Questa comunicazione può avvenire in locale, ovvero con il codice di controllo eseguito sulla stessa macchina dove si trova Virtuos («PC Virtuos»), oppure in remoto, dove il codice viene eseguito su un IPC Beckhoff connesso al «PC Virtuos» simulando la configurazione Hardware del progetto reale. Il tutto si concretizza nella visualizzazione delle movimentazioni comandate. A questo livello, il Digital Twin si presta supportare la fase di debug e all’ottimizzazione del codice macchina, presupponendo però un corretto dimensionamento degli azionamenti. Successivamente si è valutata la possibilità di estendere Virtuos a meccanismi di co-simulazione al fine estendere le caratteristiche del modello con proprietà dinamiche, con l’obiettivo di verificare la bontà di Virtuos come strumento per validare le assunzioni fatte nella fase di dimensionamento del sistema. La co-simulazione dinamica viene valutata anche per modellare la flessibilità di alcune parti critiche della macchina oppure l’effetto degli urti tra gli oggetti movimentati durante il ciclo di lavoro, fornendo un intuitivo feedback grafico.
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Ligorio, Danilo. "Virtual commissioning di una macchina automatica per la messa in passo di prodotti." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2017.
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L’obiettivo di questo elaborato di tesi è quello di testare ed analizzare le tecnologie del virtual commissioning messe a disposizione da Siemens, applicate a un caso reale. Il caso di studio preso in esame riguarda una macchina industriale di proprietà della Sitma Machinery S.p.A. per il confezionamento di generi alimentari. Nello specifico il virtual commissioning verrà applicato al modulo di macchina atto alla messa in passo dei prodotti tramite nastri trasportatori.
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Zanzani, Francesco. "Virtual commissioning di una macchina CNC: implementazione del modello e verifica delle traiettorie." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2021.
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Il lavoro di tesi si inserisce nell’ambito del Virtual Commissioning e prevede lo sviluppo del Digital Twin di una macchina transfer a tavola girevole e modulabile chiamata TDRILL, prodotta dall’azienda Giuliani. Si è scelto di concentrarsi su una specifica stazione perché rappresenta l’unità operatrice più completa presente in macchina; questa unità è chiamata Multibit ed è assimilabile ad una fresatrice CNC 3 assi.
Nel complesso il vantaggio più grande dello sviluppo del Digital Twin è rappresentato dalla possibilità di testare virtualmente la macchina senza avere, quindi, la necessità di produrla e montarla. In questo modo è possibile risparmiare molto tempo ed eseguire le prime procedure di collaudo senza il rischio di danneggiare i componenti fisici.
Nello specifico, in questo elaborato è stato descritto lo sviluppo del sistema di controllo per l’esecuzione delle movimentazioni ed è stato implementato l’ambiente di simulazione grafica dell’unità operatrice presa in esame. L’idea è quella di costruire un modello cinematico virtuale, completo ed autonomo della Multibit ed è stato fatto principalmente integrando tra loro 3 differenti software: Automation Studio, Industrial Physics e Scene Viewer.
La costruzione del modello è partita da una versione preliminare per essere successivamente completata con tutte le funzionalità CNC. Al termine della costruzione di ogni versione sono state effettuate verifiche: sulle leggi di moto, sui tempi di movimentazione e sugli spostamenti effettivi eseguiti.
Il modello costruito è in grado di simulare il funzionamento della Multibit in completa autonomia senza avere la necessità della presenza di nessun componente fisico della macchina, simulando anche il PLC e gli azionamenti. Nello specifico riceve in ingresso il file contenente le istruzioni sulla lavorazione da eseguire ed è possibile visualizzare: la Multibit in movimento, la traccia del percorso utensile eseguito e tutti i dati di posizione e velocità per ogni singolo asse.
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Flores, Ramos Bruno, and Ormazabal Mikel Urnieta. "Suitability of a virtual commissioning model for energy optimization of a gantry robot." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-17252.
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Manufacturing production systems are increasingly forced to join the path of sustainability regarding their typical room for improvement in terms of clean technology and energy usage. However, implementing these eco-friendly measures on facilities is a double-edged sword since the results are not usually guaranteed and could end up being extra energy wastages. Even though nowadays it is usually made for sequence fixing and training tasks, virtual commissioning comes alternatively into action showing up to test energy optimization attempts preventing the premature execution issues that could happen. This project has developed a VC model of a gantry crane system from a Volvo operation including energy consumption monitoring, aiming to test its suitability on energy optimization tasks. The development has been accomplished following the design and creation methodology through the use of Matlab, Codesys and Simumatik 3D and quantitative results are given specifically from different energy modeling drafts until reaching the closest result to the real system consumption. Once the true to reality model was developed, the optimization test was carried out decreasing the maximum velocity of the system behavior to see the energy consumption variation. This constitutes the ultimate test and its results are discussed coming into the conclusion that the VC model is suitable for energy optimization of the treated operation but would require reconfigurations for aggressive velocity changes.
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Ospina, Eslava David Mauricio, and Avendaño Flores Santiago. "Virtual Commissioning of Robotic Cell Using Cloud-based Technologies and Advanced Visualization System." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2021. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-19793.
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The manufacturing industry is quickly adapting to new technologies. Some of these trending technologies are virtual commissioning, virtual reality, and cloud-based technologies. This project summarizes these three technologies and aims to create a commissioning tool adapted to the 4.0 Industry. The project’s methodology was to analyse a problem and consequently create a solution that solves it. The process of designing and developing was repeated iteratively, each time an evaluation was made. The final product developed has shown that it is worth spending time introducing the cloudbased technologies inside many applications since it saves time and allows to work remotely. Applying virtual reality to virtual commissioning has proven to add efficiency. At the same time, it gives an immersive experience with a real-time display of quantitative data and the process itself in a visual mode without interfering with the actual production. With these two technologies, virtual commissioning evolves and goes a step further. This project also proved that the user experience and interface in this type of immersive applications need much attention on creating a comfortableinterface that does not fatigue or cause rejection in the user.
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Edgar, Alexander Montero Vera. "Virtual Commissioning of an industrialwood cutter machine : A software in the loop simulation." Thesis, Luleå tekniska universitet, Institutionen för system- och rymdteknik, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:ltu:diva-77401.
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The methods used today for the commissioning and validation of industrial machines requires theconstruction of physical prototypes. Those prototypes help the engineers to e.g. validate if theprogram code meant to control a machine works as intended. In recent years the development ofnew techniques for the commissioning and validation of industrial machines has changed rapidlythanks to the development of new software. The method used in this thesis is called simulationin the loop. Another method that can be benecial to use is hardware in the loop. Using thosemethods for the commissioning of a machine is called virtual commissioning. The simulation inthe loop method is used to simulate both the machine and the control system that operate thatmachine. This is called a digital twin, a virtual copy of the physical hardware and its control systemthat can be used without the need for a real prototype to be available.The software used in this thesis comes all from the company Siemens and those are TIA Portal,Mechatronics Concept Designer, SIMIT and PLCSim Advanced. By using those programs it waspossible to build a digital twin with rigid body dynamics and its control system of the industrialmodel that was given by the company Renholmen AB. This model contained all the necessarycomponents needed for a virtual commissioning project to be done without the need to be at thefactory oor.The results showed that it was possible to achieve a real time simulation, allowing the possibilityto trim the controller parameters without the need of a physical prototype. Design errors were alsofound thanks to the results of the simulation.This new technique has shown to be a useful tool due to most of the work could be done on a digitalmodel of the machine. Simulations can reduce the time to market for industrial machines and alsohelp engineers to validate and optimize the product at an early stage. This tool that can be usedto validate industrial machines before they are created.
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Niemann, Johan. "Development of a reconfigurable assembly system with enhanced control capabilities and virtual commissioning." Thesis, Bloemfontein : Central University of Technology, Free State, 2013. http://hdl.handle.net/11462/184.
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Thesis (M. Tech. (Engineering: Electrical)) -- Central University of technology, Free State, 2013The South African (SA) manufacturing industry requires developing similar levels of sophistication and expertise in automation as its international rivals to compete for global markets. To achieve this, manufacturing plants need to be managed extremely efficiently to ensure the quality of manufactured products and these plants must also have the relevant infrastructure. Furthermore, this industry must also compensate for rapid product introduction, product changes and short product lifespan. To support this need, this industry must engage in the current trend in automation known as reconfigurable manufacturing. The aim of the study is to develop a reconfigurable assembly system with enhanced control capabilities by utilizing virtual commissioning. In addition, this system must be capable of assembling multiple different products of a product range; reconfigure to accommodate the requirements of these products; autonomously reroute the product flow and distribute workload among assembly cells; handle erroneous products; and implement enhanced control methods. To achieve this, a literature study was done to confirm the type of components to be used, reveal design issues and what characteristics such a system must adhere to. Software named DELMIA was used to create a virtual simulation environment to verify the system and simultaneously scrutinize the methods of verification. On completion, simulations were conducted to verify software functions, device movements and operations, and the control software of the system. Based on simulation results, the physical system was built, and then verified with a multi agent system as overhead control to validate the entire system. The final results showed that the project objectives are achievable and it was also found that DELMIA is an excellent tool for system verification and will expedite the design of a system. By obtaining these results it is indicated that companies can design and verify their systems earlier through virtual commissioning. In addition, their systems will be more flexible, new products or product changes can be introduced more frequently, with minimum cost and downtime. This will enable SA manufacturing companies to be more competitive, ensure increased productivity, save time and so ensure them an advantage over their international competition.
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Bondeson, Per, and Stefan Liss. "Roadmap of Virtual Commissioning Inertia : An Investigation of Technical and Non-TechnicalFields of Action." Thesis, KTH, Industriell produktion, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-232436.
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Virtual Commissioning (VC) enables simulation of the combined work of mechanical, electrical, robot andautomation engineers prior to commissioning of the real production equipment. Hence, testing of areaslike collisions, PLC and robot code can be performed in risk free virtual environments and thus, errorscan be detected and corrected early in the development phase of the production equipment. Effectively,both the time and the cost of commissioning will decrease significantly. In addition, advantages likeoperator training, increased knowledge about the equipment, a more mature and optimized system priorto installation is enabled. Nowadays, the commissioning phase of a production system accounts for 25%of the total project time and research has shown that VC can decrease the commissioning time with upto 75%.However, despite all advantages and existing solutions that enables VC, it is not a standard amongmanufacturing companies nor production equipment providers to use VC today. Therefore, we wantedto investigate why VC is not a standard today.There are many barriers and challenges that must be solved prior to successful implementation of VC. Aglobal survey concerning simulation concluded that eight fields of action must be addressed in order tofacilitate the use of simulation. These eight fields address barriers and challenges and they are assumedto apply for VC too. The fields are categorized into four technical and four non-technical fields of action.The technical concerns: model re-use, modeling efficiency, integration and usability. The non-technicalconcerns: work-flow, education, acceptance and collaboration.The purpose of this project is to investigate barriers that prevent VC from becoming widely used inthe industry. Thus, each field of action was researched to better understand why VC is not commonlyused. In addition, the objective of the project is to provide an investigation regarding the technical andnon-technical fields of actions and how each of the parties along the value chain relate to each field.Therefore, the following research question was formed. What barriers are preventing VC from gainingmomentum and becoming widely used by the industry?Through our interviews we did not find any company that currently use VC.We conclude that it generallyis the non-technical fields of action that contain barriers that prevent VC from becoming a standard inthe industry. Especially, it is the organizational related barriers that are the most severe. Nowadays,there exist technical solutions that enables VC and the technical fields of action mainly treat modelingefficiency improvements. However, interoperability is considered to be the most severe technical barriertowards VC and is therefore an important area to improve. Nonetheless, we conclude that the technicalbarriers are considered less severe compared to the non-technical in terms of enabling VC to becomingwidely used.Virtuell Idriftsättning (VC) Virtual Commissioning är ett aktuellt tillvägagångssätt som underlättarinstallationen av nya maskiner för producerande företag och därmed hjälper att möta ett tuffare produktionsklimat.VC minskar risken, tiden och kostnaden för idriftsättningsprojekt, eftersom att manknyter ihop olika ingenjörsdiscipliner till en gemensam simuleringsplattform där deras arbete kan valideras.Dessa discipliner gäller primärt, mekanik, el-installation, automation och robotik. Vidare så kanfördelar som operatörsträning, ökad kunskap om utrustning och högre mognadsgrad av optimerade systemvalideras innan installationen av maskinen påbörjas. I dagsläget tar idriftsättningen 25% av dentotala projekttiden och forskning visar på att VC kan minska detta med upp till 75%.Trots att VC innebär många fördelar och att det finns programvaror som möjliggör VC är det idaginte ett etablerat tillvägagångssätt inom industrin. Därför ville vi i vårt examensarbete undersöka deunderliggande anledningarna till detta.Det finns många trösklar och utmaningar som måste lösas innan en lyckad implementering av VC. Medgrunden från en global enkät som undersökte vilka faktorer hindrar simulering från att bli ett standardverktyginom industrin utkristalliserades åtta olika områden, så kallade fields of action. Dessa antas ävengälla för VC och de åtta områdena kan delas upp i fyra tekniska-och fyra icke-tekniska områden. Detekniska områdena berör modellåteranvändning, modelleringseffektivitet, integration och användbarhet.De icke-tekniska områdena berör arbetsmetod, utbildning, acceptans och samarbete.Syftet med denna rapport är att undersöka trösklar som hindrar VC från att bli en standard inomindustrin. De åtta områdena används alltså för att undersöka varför VC inte används. Vidare vardet viktigt för oss att ta reda på hur de olika aktörerna i värdekedjan såg på varje enskilt område.Därför utformade vi följande forskningsfråga. Vilka trösklar begränsar VC från att bli en standard inomindustrin?Det var inget av våra intervjuade företag som använde sig av VC på en vardaglig basis, det var dock någrasom genomförde pilotprojekt. Generellt sätt finns det trösklar till både de tekniska och icke-tekniskaområdena, men flest trösklar är kopplade till de icke-teknisk områdena. Därför är de icke-tekniskaområdena intressanta att åtgärda primärt. Även om det är tekniskt genomförbart att implementeraVC finns det många tekniska trösklar som kan göra att arbetet med simuleringsmodeller underlättar.Vidare är det största tekniska hindret begränsad interoperabilitet mellan programvaror. Det är dock deicke-tekniska områdena som till störst del begränsar VC från att bli en standard inom industrin.
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Valeri, Nicolò. "Virtual Commissioning of a sorting system of an automatic machine for paper roll packaging." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2021.
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What is happening nowadays is, in all respects, a great industrial revolution, which has radically changed the manufacturing industry sector. The complexity of modern production plants is constantly growing, and the continuous technological progress places an enormous effort on the shoulders of manufacturers to satisfy the requirements set by an increasingly competitive market. Today the validation and testing of an automation system is a demanding task, usually performed in very tight deadlines. Therefore, the use of simulations to verify the automation system early in the design phase can be very beneficial. In this context, technologies such as Digital Twin or Virtual Commissioning come into play, both of which have, at the base, the idea of building and exploiting a completely digital replica of a real system.
Virtual Commissioning allows to test the control software of a real machine on a virtual model, or a Digital Twin, in a risk-free environment. This allows to have an early software debug and to reduce possible errors as well as reduce the commissioning time of a machine. The thesis work deals with the Virtual Commissioning of a sorter system at the entrance to an automatic machine for packaging paper rolls, in order to test the control software and evaluate its performance. From this work it is possible to understand which are the steps and the necessary tools for the realization of the virtual commissioning of an automatic machine. It immediately emerges how effective it is to work through simulations on a virtual model of the machine rather than on the real machine. Finally, the future possibilities of virtual commissioning of the entire automatic machine are discussed.
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Di, Gemma Aldo. "Virtual commissioning di un manipolatore a più gradi di libertà installato in una macchina confezionatrice di prodotti da infusione." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2020.
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L’elaborato di tesi tratta della messa in servizio virtuale per una macchina automatica, confezionatrice di prodotti da infusione, al fine di testarne il software di controllo.
Dallo studio è emerso quanto i risultati della messa in servizio virtuale possano influire sulla macchina reale.
Ci si è concentrati sui vantaggi del software utilizzato e sulle capacità dello stesso di riprodurre i comportamenti della macchina reale in quella virtuale. Infine, si è discusso delle future possibilità di messa in servizio virtuale e di ciò che si potrebbe ancora realizzare.
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Ballerini, Simone. "Virtual commissioning of an automatic boxing machine for hardware-in-the-loop control logic validation." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2018.
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Today the increase in complexity within the development process of automatic machines and automated systems and delivery times of the control project and the various mechanical movements. This is done by creating a virtual replica of the entire machine or only by the critical parts of the same through a physical simulation software.
The objective of this thesis project is the design using a virtual commissioning software useful for testing the control logic, creating a virtual 3D model of a machine and connecting a real PLC to it.
Corazza S.p.a. world leader in the construction of machines for soup cubes, melted cheeses and butter, which for the project it has provided the CAD design of the machine and the instrumentation as PC and motion controller.
The software on which the 3D model was virtualized was delivered by Siemens and its name is NX-MCD, which provided support in the first phase of the virtual modeling.
The project was divided into two parts:
The generation of the stand-alone virtual model from the 3D CAD design.
Hardware-in-the-loop connection with Schneider PLC to move the virtual model and test the control logic.
Below there is a brief introduction to the chapters of the thesis:
The first chapter presents the meaning of virtual commissioning, considering the various technologies used and what is the goal of this type of activity.
In the second chapter there is an explanation of the software used to perform the thesis activity, studying its potential and its functionality. In he last part of the chapter there is a brief introduction of the competitors on the market.
The third chapter presents the automatic boxing machine on which the project of virtual commissioning is done, studying the task of the machine and the critic part.
In the fourth chapter explain how the virtual machine was connected to the real PLC.
In the fifth chapter we describe the pros and cons that were found during this project on virtual commissioning.
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Lidell, Anton. "A Deep Dive into the Current and Future Conditions for Virtual Commissioning of Production Lines." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2021. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-20125.
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The use of virtual commissioning has increased in the last years, but there are still challenges before the software code validation method is widespread in use. One of the additions to virtual commissioning is basing it on a digital twin to allow for improved accuracy. The aim of this thesis is to review existing standards and approaches to developing virtual commissioning, as well as to explore the definitions. The chosen approach to achieve the aim, is to perform a literature review of existing research papers and interviews with knowledgeable people in the industry. First, the definitions and classifications are reviewed, then the approaches for development of virtual commissioning and digital twins are explored in the literature. In three interviews with people of varying backgrounds and competences, the views of the virtual technologies are assessed to provide insight in the industry. The findings of the literature review and interviews are among others, the apparent need for standardisation in the field and that a sought-after standard in the form of ISO 23247-1 is under way. Furthermore, the digital twin is a concept with a promising future in combination with other technologies of Industry 4.0. In conclusion, this thesis provides a deep review of the challenges and possibilities of virtual commissioning and the digital twin and could be used as starting point for further research in standardisations and improvements sprung from the new standard.
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Curri, Agustin. "Standard Software Template for Automatic Machines: Design, Implementation and Validation Through the Virtual Commissioning Approach." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2022.
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The objective of this project is to realize a reusable Software Template for the Packaging Division of the Körber Tissue Business Area. The template will be the software base of the development for all the new concept machines of the factory. It should be compliant with the OMAC PackML Standard to provide a completely general and reusable solution, including user, recipe and signal management, easy to integrate in existing production lines. In order to provide a practical ready to use solution, the software is developed analysing a new going on project on a new bundler machine for the tissue packaging area.
In the first stage, the process that the machine needs to carry out and all the functionalities involved are studied. Then, the structure of the software is decided and the template is developed, including concepts of modularity and reusability. In the second stage of the development process, a study on the trajectory planning for automatic machines is made, in order to generate a software structure that takes into account the needs of a modern machine. The VDI Guideline 2143 is considered to have a standard approach for the trajectory planning procedure.
The mechanical details of the new bundler machine are still under development. For this reason, a simulation model of the machine is created. It can already be used to test and compare different software concepts. Thanks to the virtual commissioning, the physical behaviour of a relevant part of the machine and the product flow have been simulated digitally. The simulation allowed to test the implemented template, coded into the PLC, for the single mechanical components and their synchronized movements in a safe virtual environment.
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Uddin, Md Mehrab. "Development of Advanced Process Control for Controlling a Digital Twin as a Part of Virtual Commissioning." Thesis, Högskolan i Gävle, Elektronik, 2021. http://urn.kb.se/resolve?urn=urn:nbn:se:hig:diva-37079.
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Over the last few decades, the complexity and variety of automation systems have increased dramatically. Commissioning has grown more and more critical for the entire industry. Conventional commissioning is time-consuming and expensive. It's always been a challenge in manufacturing to put new designs into production or implement new technologies, control codes, or tactics. In Virtual Commissioning (VC), control programs of the physical system's Digital Twin (DT) can be validated in Software-in-the-Loop (SIL) before the actual commissioning. The emergence of new VC tools and methods has become a tremendous advantage, bringing the values of shorter duration, flexibility, and lower risks to the commissioning process. In this thesis, advanced process control was developed using the software Matlab and Simulink in conjunction with the engineering tools S7-PLCSIM Advanced and STEP 7 TIA Portal to conduct VC. A VC approach with four key steps is taken to evaluate the possibility of validating advanced process control. The steps are modeling DT of a rolling mill, model-based control design, simulation model development in Simulink, communication between the simulation model and the PLC program using S-7 TIA Portal, and PLCSIM Advanced. Also, a simulated Human-Machine Interface was designed to operate and visualize the process. VC of the rolling mill process was verified and validated by Model-in-the-Loop (MIL) and SIL simulation. The simulation gives satisfactory results as both MIL and SIL show identical outputs of the process.
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Miklis, Peter. "Virtuální zprovoznění robotizovaného pracoviště pro studený nástřik." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2021. http://www.nusl.cz/ntk/nusl-443720.
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The diploma thesis deals with the virtual commissioning of robotized workplace for cold spraying. The theoretical part of the thesis contains an overview of the current state of knowledge in the field of virtual commissioning, the theory of crating HMI user environments, deals principles of the Rapid programming language as a tool for controlling industrial robots and analysis of robotic workplace components. The practical part defines the structure of the proposed user program and user environment, which are created using software tools Robotstudio and Screenmaker. The last part discusses in detail the steps during the implementation of the created program together with the HMI into commission, which is associated with the testing of functionalities on a real device for cold spraying. The diploma thesis also includes a user manual created for operating an industrial robot.
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Ahmad, Bilal. "A component-based virtual engineering approach to PLC code generation for automation systems." Thesis, Loughborough University, 2014. https://dspace.lboro.ac.uk/2134/16060.
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In recent years, the automotive industry has been significantly affected by a number of challenges driven by globalisation, economic fluctuations, environmental awareness and rapid technological developments. As a consequence, product lifecycles are shortening and customer demands are becoming more diverse. To survive in such a business environment, manufacturers are striving to find a costeffective solution for fast and efficient development and reconfiguration of manufacturing systems to satisfy the needs of changing markets without losses in production. Production systems within automotive industry are vastly automated and heavily rely on PLC-based control systems. It has been established that one of the major obstacles in realising reconfigurable manufacturing systems is the fragmented engineering approach to implement control systems. Control engineering starts at a very late stage in the overall system engineering process and remains highly isolated from the mechanical design and build of the system. During this stage, control code is typically written manually in vendor-specific tools in a combination of IEC 61131-3 languages. Writing control code is a complex, time consuming and error-prone process.
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Hoffmann, Peter. "On virtual commissioning of manufacturing systems : proposals for a systematic VC simulation study methodology and a new simulation model building approach." Thesis, University of South Wales, 2016. https://pure.southwales.ac.uk/en/studentthesis/on-virtual-commissioning-of-manufacturing-systems(a4f3fdc4-56b5-4429-8432-b1975d09cf08).html.
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The development of manufacturing systems is faced with progressively tightening time frames, along with growing requirements on planning quality and engineering accuracy. These demands result from significant cost constraints, shortening of product life-cycles, increasing number of product variants and economic needs for rapid time-to-market. Thus, an efficient production ramp-up including the commissioning as the crucial part, becomes more and more important for engineering companies to stay profitable. Virtual Commissioning (VC) is widely considered as promising method to address the challenges associated with real commissioning, but the simulation model building necessary for VC is affiliated with considerable effort and required expertise. VC of manufacturing systems has been a research topic in academia and industry for far more than a decade. Positive results are reported from large companies e.g. from the automotive industry, which are mostly utilising the complex and costly suites of tools in the context of the Digital Factory, rarely from SMEs. However, in particular also SMEs are forced to improve their engineering and commissioning processes, but suites of tools and methodologies used in large companies are not reasonably transferable to SMEs. Rationale for the rare use of VC, besides its general complexity, are a high modelling effort to build the necessary virtual plant models and a lack of availability of methodologies for systematic implementation and reasonable execution of VC. Thus, the main goal of this research is the development of a new systematic simulation study methodology as general guideline for planning, implementation and execution of VC. It is intended to be notably beneficial for engineers from SMEs, as helpful guideline for planning, implementation and execution of VC and to facilitate the substantially high modelling effort required for VC of manufacturing systems. Besides clarifying the requirements and specifying an environment for VC, the criteria to select an appropriate simulation tool have been established. The proposed modular, component based simulation model building has been split into specified procedures for “Low-level Component Modelling”, to be conducted for the components of the decomposed real manufacturing system, and subsequent “High-level Plant Modelling” of the virtual manufacturing system. The applicability of these new approaches has been validated by planning, implementing and conducting a VC for a trackbound transportation system with self-driving transport cars on passive tracks, which is the major subsystem of the manufacturing system used as test-bed at the UASA Hannover. As one main result, a novel workflow for Low-level Component Modelling has been proposed that aims for the gradual relocation of this modelling task as far as possible to the origin of components, in the end the component manufacturers should provide together with the deliverable components their mechatronic component models. This is related to a novel proposal for exchangeable mechatronic component models and an outlined possible implementation with AutomationML.
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Riabichev, Maxim. "Modelling a Scalable, Reusable and Realistic Digital Twin for Virtual Commissioning : Investigating possibilities with custom SmartComponents in ABB RobotStudio." Thesis, Mittuniversitetet, Institutionen för elektronikkonstruktion, 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:miun:diva-37298.
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The Advanced Manufacturing section at ÅF Pöyry AB is exploring the possibilities of virtual commissioning and digital twins. As part of this exploration, this thesis sets out to demonstrate a method of developing scalable, reusable and realistic digital mechatronic models – the heart of a digital twin – for the virtual environment in RobotStudio. Research has shown that one of the major obstacles to implementing virtual commissioning as a standard in industry today is the lack of scalable and reusable digital twins. This is also the experience of ÅF Pöyry AB. After reviewing existing and proposed methods for developing digital twins, this thesis explains the necessary steps for developing a SmartComponent in RobotStudio, using the programming language C#. The results show that the SmartComponent developed is scalable and thus reusable. It works with grippers with any number of fingers and allows gripping by applying pressure to the target object from both the outside and the inside. It is also realistic in the sense that the interaction between the grippers and the objects to be picked in the virtual environment behaves and looks like it does in reality. The implementation of the SmartComponent developed is much faster and less complex than the method used today at ÅF Pöyry AB. The downsides of the developed method are the added competence required of the automation engineer and the risk that the digital twin may not be future-proof.Avdelningen Advanced Manufacturing på ÅF Pöyry AB utforskar möjligheter med ”Virtual Commissioning” och ”Digital Twins”. Som ett led i detta projekt har syftet med detta examensarbete varit att visa ett sätt att utveckla en skalbar, återanvändbar och realistisk digital mekatronisk modell för den virtuella miljön i RobotStudio. Tidigare forskning har visat, i linje med ÅF Pöyry AB:s satsning, att ett av de stora hinder för att Virtual Commissioning ska kunna implementeras som standard i industrin idag är bristen av skalbara och återanvändbara digitala tvillingar. Efter en genomgång av den befintliga och föreslagna metoden för att utveckla digitala tvillingar presenteras de nödvändiga stegen för att utveckla en SmartComponent för RobotStudio, med programmeringsspråket C#. Resultaten av utvecklingen och testen har visat att den utvecklade SmartComponent är skalbar och återanvändbar: den fungerar med gripare oavsett antal fingrar och den tillåter gripning både genom att applicera tryck på plockobjektet från utsidan och insidan. Den är också realistiskt på så vis att interaktionen mellan griparen och objekten som ska plockas i den virtuella miljön beter sig och ser ut som i verkligheten. Implementeringen av den utvecklade SmartComponent är också mycket effektivare och mindre komplex jämfört med den metod som används idag på ÅF Pöyry AB. Nackdelarna med den föreslagna metoden är de extra kompetenskraven för automationsingenjörer och risken att den digitala tvillingen inte är framtidssäker.
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Ekedahl, Adam. "Förändring av arbetssätt med hjälp av emulering : Vid automationsprojekt mot industrin." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-15831.
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På uppdrag av Projektengagemang AB i Skövde har detta projekt genomförts för att studera möjligheten att kvalitetssäkra automationsprojekt bättre med hjälp av emulering. I projektets sammanhang innebär det att representera hela eller delar av automationssystemet virtuellt. För att lyckas med projektet har forskning inom områden som projektledning och virtuella miljöer studerats för att undersöka vad som i dagsläget är möjligt att genomföra. Med hjälp av litteraturen utformades ett intervjuprotokoll för genomförande av en intervjustudie. Beställande och levererande företag av automationsutrustning har bidragit för att ge en realistisk bild av hur automationsprojekt genomförs, kvalitetssäkras samt vad som idag är problematiskt. Sammanställningen och analysen av intervjustudien tyder på att vikt skall läggas vid planering och nedbrytning av projekt, för att ha en tydlig plan från början. Samt att virtuella miljöer kan användas för att testa programkod tidigare i projekt, alltså i mindre kritiska lägen. Efter en granskning av Projektengagemangs förutsättningar i förhållande till intervjustudien framkom att det finns brister och förbättringspotential gällande programstruktur och kvalitetssäkring. Förslaget för att öka kvalitetssäkringen med hjälp av emulering innefattar skapandet av ett arbetskoncept där en emuleringsmodell tillsammans med en kravspecifikation används för framtagning av ett grundprogram. Samt att företagets konstruktionsgranskning utökas till att inkludera kontroll av både programmering och eventuell emuleringsmodell. I förslaget till Projektengagemang lämnas 2 olika konfigurationer som skulle kunna användas för att inkludera skapandet och användning av emuleringsmodeller i projekt. Vilket skulle öka kvalitetssäkringen markant. I dagsläget påverkas inte ledtiden markant med införandet av emulering, dock finns möjligheten på längre sikt. Ytterligare kravställningar behöver tas i beaktning innan val av mjukvaror sker, eftersom förutsättningarna för varje projekt påverkar byggnationen av en emuleringsmodell.
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Amato, Beatrice. "Virtual comissioning and software developement for an automatic machine prototype." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2021. http://amslaurea.unibo.it/22466/.
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The objective of this work is to realize a prototype of an automatic machine for the pharmaceutical industry. This model aims to produce a new generation of drugs.
The process, that needs to be followed to produce a new type of drug, starts from the medicine in liquid form, then through a drastic lowering of the temperature, it passes to the solid state, and then is freeze-dried, in a sterile environment. The final result is a medicine in beads form.
The machine is mainly composed of three robots and a dosing arm unit.
Starting from a reservoir where the drug is in liquid form, the dosing arm unit sucks the liquid through ninety-six pipettes.
In the initialization phase, the content of each pipette is emptied inside the weighted tubes by a dosing arm unit, then the first robot proceeds to the gross weighing of the test pieces. If all the doses are equal, then the dosing arm unit can proceed with the production of the beads, starting by sucking again the fluid from the reservoir.
For nominal dosing, the dosing arm unit moves above a nitrogen-cooled plate, at a temperature of -110°C and let each pipette discharges a drop of liquid on to the freezing plate.
Trays are handled by a pair of robotic arms.
Since this is a completely new type of machine, the different phases are being studied and under development, so most of them have not yet being manufactured.
For this reason, it has been created a simulation model that forms the basis of the Digital Twin, since it can already be used at a very early stage of the development process to test and compare various concepts.
A 3D graphic model of the machine has been devised and thanks to the virtual commissioning, the physical behavior of the machine has been reproduced in a computer-generated way, through a software simulation applied to the Digital Twin.
This safe virtual environment allowed to test the logic programmed into the PLC, for the single components and the synchronization of the whole machine movements.
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Bini, Cosimo. "A pick-and-place robot for coffee capsules: virtualization and trajectory design." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2020.
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Even if Virtual Commissioning is not widely spread among industries yet, it offers plenty of advantages for the manufacturing of productive plants, that consist of reduced commissioning time, optimization of the code, better synergy between mechanical and software design. However, due to the cost of the requested investments, only big firms employ it in their production processes. This work aims at providing an example of how Virtual Commissioning can be applied to an automatic machine and how it can be used to improve the kinematic behaviour of two degrees of freedom manipulator, that moves coffee capsules into carton boxes. In particular, the simulations deal with the modifications of the parameters of the current trajectory and the test of a different kind of path for the robot, paying attention to collisions with the other parts of the machine.
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Poblacion, Salvatierra Itxaso. "Simulation software for automation industry : Factory I/O and KUKASim software." Thesis, Högskolan i Gävle, Avdelningen för elektronik, matematik och naturvetenskap, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:hig:diva-27271.
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This thesis has two aims, both related with simulation programs. The first one is to analyze the viability of using Factory I/O as a tool at the University of Gävle for teaching and understanding the PLCs and the ladder programing. The second one is do a 3D model of the robotics laboratory to use it with the KUKASim and after that find a method to transfer code from KUKASim to the actual robots.Factory I/O has been install and use with a Siemens PLC, which was programed in Siemens TIA Portal. The evaluation of the software as a teaching tool has been done according to a supposition of how much time could it take to an average bachelor degree student in automation to create a functional project. In order to determine that, a demo has been done, which consist on a process in where a box enters by a conveyor. There are two ruts for the box to exit, straight or to the left, and the direction is choose by moving a switcher in the PLC. After analyzing finishing the demo, it has been determinate that it could take around 4 hours to complete a functional project.For the KUKASim part, KUKASim was already installed. However, during the development of this project it was updated from 2.2 to 3.0.4 which caused a minor issues; the SketchUp model could not be imported to 2.2 version and by the time that the upgrade was made the 3D environment of the robotic laboratory was already made in KUKASim.On the other hand, the Office Lite software was needed to be installed in order to transfer the code from KUKASim to the real robots, but due to some license issues, the installation was done at the end period of the project. The connection of both software was not possible to make, still, during the time that Office Lite was not available, an alternative method to transfer the code was found. The program files were download from KUKASim and transfer to the robot with WorkVisual.The conclusion of the thesis is that Factory I/O could be used as a learning and teaching tool because is an easy program to work with. All the same, KUKASim is a multifunctional software, which has make it possible to achieve both of the purposes for corresponding part of the project.
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Heras, Aguilar Sergio. "Comparison and visualization of robot program modifications : Applied on ABB industrial robots at Volvo Cars Corporation." Thesis, Högskolan Väst, Avdelningen för produktionssystem (PS), 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-11510.
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Volvo Cars Corporation creates robot programs off-line for all new robot implementations for virtual commissioning. These virtually created robot programs are then downloaded to the real robot, after the installation has been carried out, to be tested before they are fully operational. These tests are spanned from robot installation until full production, adjusting the robot programme according to Volvo Cars specification and correcting errors that the robot program may have. Changes of the robot programs will be saved each time it is modified, generating a series of backups for each robot until the robot is correctly adjusted along all the steps of the process. To improve the offline programming there is a necessity for visualize the modifications made during the physical robot commissioning. The objective of this thesis is to identify, categorise, quantify and visualize modifications between each different backup of a robot. A software application has been developed using Microsoft Visual Studio using C#. The application is designed in windows for different types of data. It enables the user to compare two robot programs (two different backup programs from the tests) from one robot and see the result between them graphically. The graphs are designed interactively so that the user can filter the information to see the desired data from the robot programs comparison. Key performance indicators (KPIs) has been specified for RobTargets and Procedures according to Volvo Cars Corporation requests. These KPIs are implemented and visualised in a graphical representation.
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Thongnuch, Sathida [Verfasser]. "An approach to generating high-fidelity models for the virtual commissioning of specialized production machines and cells using MCAD models / Sathida Thongnuch." Hamburg : Helmut-Schmidt-Universität, Bibliothek, 2021. http://d-nb.info/1241977119/34.
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Ravi, Rahul. "Digital Twin of an Automatic Machine Using Unity and Prespective Software." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2020.
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Digital Twin is the modern way of prototyping. It is a new layer on top of an existing model, extending the possibilities. This thesis work was carried out and developed at the research laboratory “LIAM LAB”. The main focus was to study the efficacy in developing a Digital Twin of an automatic machine in detail. It is a packaging machine (Technocoil 2200) from “SICA” using PRESPECTIVE, a Digital Twining software based on a game engine UNITY3D. Digital Twin tools and solutions are offered by many major companies, but these have the potential disadvantage of vendor lock-in. Although these brands claim to be open, their tools do not operate very well with third-party software. This makes many users to opt for openness which will help in integrating many features as per their requirement. Another main factor is providing high resolution simulations with an ability to solve complex physical problems which could be handled by Unity.
The process of modelling a Digital Twin is studied extensively in this thesis work. But, in particular the tube guide part of the machine was considered, and its Digital Twin was modelled using Prespective and subsequently the interfacing of the model in Prespective with a PLC was implemented. Finally, the interfacing is validated by forcing values from controller and visualizing the outputs in Unity.
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Mordenti, Eugenio. "Sviluppo di un modello elastodinamico multibody di una macchina utensile CNC a 3 assi mediante il software MSC Adams." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2020.
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Questo progetto si pone l’obiettivo di rispondere alle esigenze di virtual commissioning, strettamente legato al concetto di industria 4.0. La stesura dell'elaborato è stata svolta in collaborazione con l’azienda Giuliani (Bucci Automations S.p.A. Division) di Faenza.
L’obiettivo principale di questo studio è realizzare un modello meccanico elastodinamico multibody di una macchina utensile CNC a tre assi mediante il software MSC Adams.
Con questo tipo di modello è possibile indagare l’andamento delle forze e delle coppie che gravano sulla macchina; inoltre è possibile valutare lo spostamento/velocità/accelerazione dei componenti più rilevanti, in funzione delle leggi di moto assegnate sui tre assi.
Nella prima parte dell’elaborato si fornisce una breve descrizione della macchina, ponendo particolare attenzione alle operazioni svolte all’interno del CAD per riuscire ad importare correttamente la macchina all’interno di Adams. Successivamente, si illustra la strategia di modellazione utilizzata per i vari sottosistemi della macchina utensile; in particolare, si analizzano in dettaglio il sistema guida-pattino e la trasmissione meccanica.
Infine, nell’ultima parte, si presenta il modello completo, illustrando gli schemi dei tre assi della macchina; in particolare si mostrano i vincoli e le forze che agiscono su ogni coppia di corpi e si presentano le leggi di moto utilizzate e come si sono modellate all’interno di Adams.
Al termine dell’elaborato si propongono i risultati preliminari ottenuti dalla simulazione, giustificando l’utilità della realizzazione del modello elastodinamico.
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Kutík, Jakub. "Simulace výrobní linky." Master's thesis, Vysoké učení technické v Brně. Fakulta elektrotechniky a komunikačních technologií, 2019. http://www.nusl.cz/ntk/nusl-400614.
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The aim of this thesis is to create a custom application to simulate production lines. The first part explains the main reasons, benefits and current trends in the field of virtual commissioning and describes several simulation tools and engineering tools from Siemens. The second part is devoted to a detailed description of features, capabilities and application interface of the PLCSIM Advanced simulation tool. The third part is devoted to design and realization of the custom simulation application, which can be used for create conveyor lines and validate user PLC program in cooperation with PLCSIM Advanced tool. This simulator was created using Unity3D game engine and C# programming language. In the last part of the thesis, a simple simulation task is created in the simulator and is tested using PLC program and visualization created in the TIA Portal engineering framework.
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Lorenc, Tomáš. "Virtuální zprovoznění robotického pracoviště pro manipulaci s výrobkem." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2021. http://www.nusl.cz/ntk/nusl-444299.
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The diploma thesis deals with the issue of virtual commissioning of the workplace and the commissioning of communication channels needed for this purpose. The theoretical part describes the benefits of virtual commissioning, robot and PLC programming and effectors for robots. The practical part deals with the design of the final robot effector, virtual commissioning using the programs Process Simulate and TwinCAT 3, communication between programs and creation of programs for the workplace.
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Čefelín, David. "Virtuální zprovoznění paletizačního/depaletizačního pracoviště." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2020. http://www.nusl.cz/ntk/nusl-417458.
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This diploma thesis is dealt with the virtual commissioning of a palletizing line, which is palletized using an industrial robot. In the theoretical part I describe the applications, divisions and effectors of the industrial robots and the reasons and the benefits of palletizing. Furthermore, the issue of virtual commissioning is described, including sensors, that are served for the proper operation of the workplace and the virtual simulation. In the practical part I describe the future workplace, creating a simulation and the program in the RobotStudio software.
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Antoni, Carlotta. "La Validazione GAMP5 di macchine automatiche per il settore farmaceutico: proposte migliorative." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2021.
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Il settore farmaceutico è regolato da una serie di norme atte a garantire un elevato livello di qualità del prodotto, per salvaguardare la salute degli utilizzatori. Il rispetto di tali norme deve essere dimostrato attraverso l'attività di validazione, ed è obbligatorio per la commercializzazione dei farmaci. Le GMP, Good Manufacturing Practice sono l'insieme delle norme che regolano la produzione di prodotti farmaceutici. Vista la complessità delle GMP, le case farmaceutiche possono usufruire delle GAMP, Good Automated Manufacturing Practice, un insieme linee guida che forniscono indicazioni utili per ottenere la validazione GMP. Tale elaborato si pone l'obiettivo di esaminare il mondo della validazione farmaceutica, con focus sulla validazione OQ, Operational Qualification, di macchine automatiche per il packaging farmaceutico. Infine, viene fornita una proposta volta a migliorare la validazione OQ attraverso l'implementazione del Virtual Commissioning, una tecnologia che permette la messa in servizio virtuale di una macchina, utilizzando come caso studio un'azienda leader nella produzione di macchine automatiche per il confezionamento di prodotti farmaceutici.
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Einevik, Johan, and John Kurri. "Emulering av en produktioncell med Visionguidning : Virtuell idrifttagning." Thesis, Högskolan i Skövde, Institutionen för ingenjörsvetenskap, 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:his:diva-14143.
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Genom att använda sig utav en virtuell kopia utav en produktionscell kan programmering och funktionstester av olika paneler testas i ett tidigt stadie. En virtuell kopia bidrar också till enklare felsökning och minskning av kostnader vid idrifttagning. Tanken med projektet är att undersöka i vilken utsträckning som emuleringsmodellen kan ersätta den riktiga cellen vid ett funktionstest för leverantören. Det som också undersöks är i vilken utsträckning riktiga CAD-ritningar kan användas och vilka krav som ställs på ritningarna för att underlätta emulering. Projektet hade flera utmaningar och en av dem som uppkom under projektets gång var problemet med att det inte gick att emulera säkerhetssystemen. Detta löstes genom att bygla alla säkerhetskretsar i PLC-programmet. En viktig del i emulering är kommunikation mellan de olika programvarorna i systemet. I projektets visade det sig fördelaktigt att dela upp programmen i emuleringssystemet för att fördela resurserna över tre datorer. Att använda sig utav en emuleringsmodell istället för en riktig produktionscell är fortfarande i forskningsstadiet men genom projektet har många användningsområden identifierats och skulle kunna förändra idrifttagning i framtiden.Using a virtual twin of a production cell, makes it possible for programming and different functional testing of panels to be performed in early stages of development. A virtual twin contributes to a simpler debugging and to identify problems and minimize cost in commissioning of the production cell. The aim for the project is to investigate how well an emulated cell will perform compared to the real production cell in a factory acceptance test. Another objective is to investigate how you can use real CAD models in the emulation and what type of criteria the models should meet. The project had a lot of challenges and one of them was the difficulty to emulate the safety systems. This was solved by bypassing the safety in the PLC program. One important thing about emulation is communication between the different software used in the system. In this project, it proved successful to distribute the software on three computers to ease the workload of the programs used in the emulation. To use the emulated model instead of the real system is still in the research phase but in this project a lot of useful applications could be identified that could change commissioning in the future.
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Adolt, Lukáš. "Virtuální zprovoznění robotizovaného pracoviště pro obloukové svařování." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2021. http://www.nusl.cz/ntk/nusl-443715.
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This diploma thesis is focused on the design of a robotic workplace for arc welding and its subsequent virtual commissioning. The summary deals with knowledge from industrial robotics and arc welding, the system analysis is focused on the composition of the workplace and the principle of arc welding, including acting influences. In the practical part, several variants of the solution are proposed, the most suitable variant is processed in the form of a 3D model. This model is then simulated, including all processes, a control program is created, and virtual commissioning of the workplace is demonstrated.
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Šimůnek, Petr. "Digitální zprovoznění robotizovaného pracoviště pro studený nástřik rotačních dílů." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2021. http://www.nusl.cz/ntk/nusl-444281.
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This work deals with the virtual and later real commissioning of the workplace for cold spraying of rotating parts, which is located in the laboratories of the Institute of Materials Science and Engineering, Faculty of Mechanical Engineering, Brno University of Technology. The workplace put into operation in this way serves the employees of the mentioned institute for experimental activities in the field of cold spraying. The theoretical part of the thesis describes all the essentials associated with virtual commissioning and the theory of cold spray. The practical part then deals with the creation of a robotic program, including the user interface, which is used to control the workplace. Part of this diploma thesis is also the realization of the connection between the external motor driver and the robot controller via the PROFINET communication bus.