Virtual commissioning offers many benefits

The next Start me up Monday on January 22, 2024 will be all about “virtual commissioning”. We spoke to Robert Fellner in advance. He is a lecturer and researcher at UAS Technikum Wien (Industrial Product Life Cycle Technologies competence field) and will give the introductory lecture on the topic.

What is virtual commissioning?

Robert Fellner: We understand virtual commissioning as a collection of various preliminary simulations in the course of the (further) development of mechatronic systems. The simulation of manufacturing industrial plants and plant systems is the main focus, in order to implement aspects of real commissioning in parallel with the development process and thus reduce (or at best avoid) errors. As is often misunderstood, this does not deal with the calculation and simulation of finite elements: the simulations are much more aimed at testing processes and programming and testing circuits in the interaction of different mechatronic systems. In recent years, other sub-areas have been added to these simulation environments of virtual commissioning: For example, the (advance) visualization of plants/plant systems and other uses of the simulation environments created, such as for virtual training of plants, smart maintenance, and much more, are becoming increasingly topical.

What are the advantages of virtual commissioning?

Robert Fellner: During the development of a production plant, it is almost impossible to avoid errors. A pre-simulation of a developing plant primarily reduces errors that would otherwise only be detected during actual commissioning. The aim of virtual commissioning is therefore to be able to detect and rectify any errors that occur as early as possible – this saves money and reduces the actual commissioning time.

How complex is it to reproduce the behavior of different and complex machines with a simulation for virtual commissioning?
Robert Fellner: Just as difficult as answering this question. The question already includes the fact that the complexity goes hand in hand with the degree of use of heterogeneous systems and the complexity of the system/machine itself, in other words: the fewer different elements interact with each other, the easier it is to simulate. In the best case, behavioral models of producers already exist: then it is “only” more a question of integrating the models: if there are no behavioral models and the plant is very complex (or creating the behavioral model is very complex), then it may be necessary to cut back and choose a higher level of abstraction.

Which steps / levels are necessary for virtual commissioning?

Robert Fellner: It starts with the specifications, which anticipate the corresponding tasks. The most concrete questions possible must be derived from the tasks. Once these have been defined, the time when a simulation is to be implemented and the depth of simulation (or, as before, the level of abstraction) that can be selected – these answers are then determined by the right tool. Depending on the available data, the next step is to prepare the existing data for simulation and integrate it into a corresponding simulation. Implementation and potential adaptation of the virtualized system are then usually a cyclical process, and the V-model can be used as a good guide for the sub-steps.

What potential is there for start-ups in this area of emerging technology?
Robert Fellner: Startups per se have the advantage of being able to act more flexibly than larger corporations. This seems very favorable in the (still?) niche of virtual commissioning, as the process details of the plants can be very different. Legal issues, such as the transfer of simulation models, also still seem to pose a major difficulty for established companies. Here, start-ups with speed, innovative solutions and courage can claim many advantages for themselves.

In which areas can virtual commissioning be improved in the future?

Robert Fellner: I see the biggest development step ahead of us in the creation of simulation models: creating simulation models of CAD models “by hand” is time-consuming and in turn harbors new sources of error. Some companies have already recognized this and are moving in this direction. There must be a transfer of models between producers and customers of the systems so that partial models can be reused more efficiently. Another approach here is the generic creation of such simulation models; a lot is currently happening in research in this area, including here at the FHTW.

Where is virtual commissioning currently being used? And in which areas could they be used in the future, in 10 to 20 years’ time?

Robert Fellner: We have been familiar with pre-simulation for process engineering systems for decades. Thanks to Mr. Wünsch’s dissertation in 2007, “Methods for the virtual commissioning of automated production systems”, virtual commissioning is also known for mechatronic systems in German-speaking countries. However, due to the additional effort involved in creating simulation models and the lack of tools to implement them, until a few years ago it was only economical to implement them in niches (primarily in special machine construction) – this has now largely changed. However, the efficient tools are now available, as is the know-how. The effort required to create models has therefore decreased significantly. I am rather critical of the fact that virtual commissioning will still be referred to/used in this way in 20 years’ time, but the methods from virtual commissioning will certainly still be valid in the coming decades when these simulations are used in other areas. Newer terms such as “model-based systems engineering” or “virtual product life cycle” use virtual commissioning methodologies. In my view, these are therefore natural extensions that are also still being developed. In order to be able to implement these topics, it therefore makes sense to master the methodologies of virtual commissioning.

How are virtual systems used in teaching?
Robert Fellner: We have found that subtasks of virtual commissioning can be used in teaching on various topics. For example, students without programming experience can implement “real” virtual robot sequences safely and intrinsically at their own pace.

Info about the project “INVIS”:
Since 2021, Robert Fellner’s work in the research project INVIS – “Integration of virtual systems in teaching and laboratory exercises” (MA23 project 29-11) has been supported by the City of Vienna.
Click here for a link to the project.

Find out more at the event, where Robert Fellner will be joined by other experts such as Johannes Rauer-Zechmeister (Portfolio Expert at Siemens, Business Development) and Marcus Schneider (Territory Sales Manager at Visual Components).

More details about the event: Here.

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