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Process Simulate Virtual

Commissioning

Shay Shomroni

Director Industry Solutions


Manufacturing Business Group
shay.shomroni@siemens.com

2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
Siemens PLM Software
Tool
Shop-floor challenges change
procedure

Conveyor
Throughput optimization
reaction
Sensor
positioning

Electrical
device
signals

Handling
variants

Safety
procedures HMI synch
with tools

2011. Siemens Product Lifecycle Management Software Inc. All rights reserved
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Virtual Commissioning

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


code, and automation scheme with a virtual model of a factory

Faster
Shorter time to production
Quicker change cycle

Better
High quality PLC code
Optimized performance

Less Expensive
Cost of production stop
Cost of prototype parts

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Story board

OEM XYZ Supplier 123

+
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Supplier Analyze: What is required?

Tooling
Clamps and Pose sensors address
new variant

Robotics
OEM Standard program considers
pedestal gun and new variant

Control
HMI test for clamps, safety procedures
and E-Stop pass
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EBZ Case Study

https://sales.industrysoftware.automation.siemens.com/accesscount/188
28/EBZ-Group-Customer-Testimonial-R7T1A1

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Primary Line Builder Challenge

Validate OEM changes faster and more accurately

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Tooling Tasks

Adaptation of Process, based on existing design


Define clamp functionality and specific behaviour
Mapping to PLC Signals and dynamic testing

Change the existing Process to multi variant


Correct Material Flow
Variant Detection
Mapping to PLC Signals and
dynamic testing

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Tool design Example

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OEM instructions

OEM XYZ Supplier 123

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The Use Case: Requirements

Peripheral Resources
Safety

Variants
Synchronization

Native Language
OEM Standards
Maintenance

Traditional Work cell Simulation

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Robotics engineers tasks

Manage changes after receiving a new path:


Variant Branching
Synchronize robots to PLC
OEM Standard Robot Code
Download programs and test

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Robotic Simulation

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Event-Based Simulation

Realistic cycle time


Conveyor control (physical, logics)
Material handling between stations
Load, steady state, variants and shutdown
scenarios
Time based
OP 1

OP 2
Event-based
OP 1 OP 3

A OP 2

NOT A OP 3
2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
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Supplier Analyze: What is required?

Tooling
Clamps and Pose sensors address
new variant

Robotics
OEM Standard program considers
pedestal gun and new variant

2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
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Control virtual commissioning

Mechanical Electrical

Kinematics Inputs / Outputs


Robot Programs Logic
Mechanical Sequences Interlocks
Layout HMI
Clearances Diagnostics
Cycle Time Safety

Evaluate Mechanical and Automation System behavior


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Virtual Commissioning

Easily create a realistic shadow of a production


environment
Test & Debug PLC code
Long before the real system is build
Minimize impact on existing environment
Use real PLC H/W or emulated S/W

Start of
Production

Test earlier Dont disturb


production

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VC Environment

Process Digital Process Automation


Knowledge Design Validation
Simulation

Real Time
Signal Signal
Mapping Exchange
OPC (Client & Server)
Controls

PLC Code

PLC HMI

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Virtual Commissioning Demo

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Life Cycle Processes
(Current State)

Estimating Planning Design Construction

Process Planning & Documentation

Controls Design

Workcell Simulation

Equipment Design

Program
Installation Debug Try-Out
Robots

Cost and Time

2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
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Life Cycle Processes
(Future State)

Estimating Planning Design Construction

Process Planning & Documentation

Controls Design Debug

Workcell Simulation OLP


(Enhanced) (Enhanced)

Equipment Design

Installation Debug Try-Out


(Physical)

Cost and Time

2010. Siemens Product Lifecycle Management Software Inc. All rights reserved
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AMT Testemonial

https://sales.industrysoftware.automation.siemens.com/accesscount/24847/Virt
ual-Commissioning-Video-AMT-Testimonials-R7T4N3

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Benefits

Estimating Planning Design Construction

Earlier
start of production
OEM
Lower cost on changes

Major Riskreduction:
Tier 1 Mature processes
Primary LB Right the first time
Standardization of processes and components

Tier 2 Collaborative and Efficient Engineering


Eng Houses Validation reduces risks on site

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Process Simulate Take Aways

Highly functional & easy to use


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

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THANK YOU!

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