Designing and operating plants and processes virtually
With WinMOD, you can simulate your entire automation system in a virtual space.
Simulate down to the smallest detail.
Virtual commissioning
Test control programmes safely and quickly before transferring them to the actual plant.
Virtual operation
Perform service processes regardless of the location of the machine/system and prepare optimisations during ongoing operation.
Virtual machine / system
Creation of functional 3D images of real machines that can be connected and put into operation without any software changes.
Virtual commissioning
Modelling and operating plants virtually
Virtual commissioning (VC)
Virtual commissioning (VC) corresponds to real commissioning with a virtual machine or system according to current practice. The connected automation system can be real (HIL) or virtual (SIL).
In practice, several different aspects come together when commissioning a real plant.
- Subsequent clarification of the actual functionality of components and systems
- Continuation of software development during commissioning
- functional testing of the software with the actual system
- Parameterisation and optimisation of the automation software with the actual plant
- Briefing of the operator and service personnel
These tasks are very uncertain in terms of time. They are costly because they take place on site, they are risky and they can drastically delay planned commissioning dates.
The innovative alternative is virtual commissioning (VC). In terms of content, this is a real commissioning of the real control system and the original software in conjunction with a virtual machine/system. The virtual machine/system behaves sufficiently similarly to the control system to enable it to be put into operation. The work involved in commissioning can thus be carried out together with the project participants, regardless of location and state of completion.
Virtual operation
After the real machine/system has been put into operation, the virtual machine/system is available for further use.
Service processes can be supported regardless of the location of the machine/system, and optimisations can be prepared during ongoing operation.
Digital twin or shadow plant
When a real or virtual automation system is operated permanently in parallel with a real plant in conjunction with a virtual plant, this is referred to as a digital twin or a „shadow plant“. During plant operation, optimisations or process changes can be prepared without downtime and without endangering the real plant. Particular attention should be paid to the constant adaptation of the shadow plant to the structure and behaviour of the real plant. This enables a constant comparison between real and virtual behaviour.
The digital twin supports the implementation of migrations. This applies in particular to the replacement of automation systems with extreme requirements for recommissioning while the plant is in operation.
Virtual machine / system
The virtualisation of machines and plants is an intensification and extension of plant simulation.
The result is a model that corresponds to reality in terms of behaviour and communication to such an extent that it can be connected to a real automation system without any software changes and put into operation.
Virtualisation of machines and systems
Since 1991, the WinMOD system platform has been prepared for these objectives. In 2002, the first prototype for a virtual machine tool was created. In 2005, the virtual plant was part of a specification for the VC of a manufacturing cell in automotive engineering.
Virtualisation itself already provides an initial utilization. It creates a functional specification from the perspective of the automation engineer. Deficiencies and errors are identified and rectified at an early stage. A communication platform is available for all subsequent utilizations, which is perceived and understood in the same way by all parties involved.
The virtual machines/systems are created in the WinMOD project from the engineering data of the upstream or parallel engineering processes and must be kept consistent with these.
Virtualisation in process automation
For virtualisation in process automation, the WinMOD system platform has been gradually expanded to include industry- and technology-specific libraries, which enable the necessary simulation depth for holistic modelling. WinMOD communications are utilized for integration into a runtime system for collaboration with specialised simulation tools.
Virtualisation in factory automation
For virtualisation in factory automation, the WinMOD system platform has been expanded to include system modules for WinMOD-SIMLINE with 3D visualisation and technology libraries with material flow capability. This allows machines and systems to be virtualised for all uses from an automation perspective.
