Virtual Commissioning Of Manufacturing Systems A Review And New Approaches For Simplification
---
paper_title: AutomationML - the glue for seamless automation engineering

paper_content:

This contribution presents the basic architecture of the neutral data format AutomationML developed by the companies Daimler, ABB, Siemens, Rockwell, Kuka, Zuhlke, netAllied and the universities of Magdeburg and Karlsruhe. AutomationML serves for the data exchange between manufacturing engineering tools and therefore supports the interoperability between them. It covers information about the plant structure (topology and geometry) and the plant behaviour (logic and kinematics). The first version of AutomationML has been presented at the Hannover fair in 2008.
---
paper_title: III-Phase Verification and Validation of IEC Standard Programmable Logic Controller

paper_content:

The objective of this paper is to define an integrated approach for offline verification and validation of the control logics to provide absolute solution by implementing the III-Phase V&V method in a manufacturing industry. The control logic plays vital role in an agile manufacturing system for proper functioning of the FMS. The effort to integrate the formal verification techniques with virtual commissioning is emerging, which is still not in a full fledged industrial usage, due to the isolated thinking of the user about formal verification techniques. Existing techniques like simulation has not been able to detect the hidden errors, which may propagate from one workcell to another workcell in a long run and create a complete breakdown in the manufacturing unit. These errors required to be carefully tested before the real time implementation. Control logics play a vital role to reduce the down-time and ramp-up time in a manufacturing industry. We need an integrated approach and techniques to support the consistent running of the production cycle. This paper explained about the positive aspects of manual and software based automated and virtual commissioning techniques to provide an applicable solution to the fast paced manufacturing industries.
---
paper_title: COSIMIR transport: modeling, simulation and emulation of modular carrier based transport systems

paper_content:

More and more industrial enterprises tend to validate their planning for new factories using simulation. Production environments often contain automated transport systems to move items between different work stations. We present a solution for modeling transport systems with respect to their interaction with all peripheries like robots and treatment machines. Modeling follows the process of mechanical assembly by putting together constructional components in 3-D space. Models of devices are of sufficient physical and electrical accuracy to test unmodified controller programs in a virtual commissioning phase to save time at the real start-up. In emulation, real controllers connect to the model to test and optimize control programs. In contrast to conventional discrete event simulation software, developers can play with the model during simulation to test its reaction and perform event of fault analysis. Simulation results are suited to secure design decisions of planners and reduce the risk of incorrect planning. Easy to recognize 3-D geometry and simulation interactivity qualify models for presentation and personnel training. Finally, simulation reveals suboptimal behavior and makes optimizations easier.
---
paper_title: Formalization of existing PLC Programs: A Survey

paper_content:

In recent years, the interest in the formal- ization of PLC programs increased. The paper pro- vides a classification scheme for the works done in this field. This scheme includes the sources used for formalization, the level of the formalization process (i.e. the complexity of structures that could be han- dled by the approach), the aim of the formalization (Re-Engineering or Verification) and the formal model used to represent the formalized PLC pro- gram. The scheme is applied to several examples.
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paper_title: Digital Factory - Simulation Enhancing the Product and Production Engineering Process

paper_content:

The digital factory concept offers an integrated approach to enhance the product and production engineering processes and simulation is a key technology within this concept. Different types of simulation, such as discrete event or 3D-motion simulation can be applied in virtual models on various planning levels and stages to improve the product and process planning on all levels. The focus and key factor is the integration of the various planning and simulation processes. In an advanced stage simulation technology can be applied in the digital factory concept to enhance the operative production planning and control as an integrated process from the top level to the factory floor control.
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paper_title: Interface driven domain-independent modeling architecture for "soft-commissioning" and "reality in the loop"

paper_content:

As industrial manufacturing and automation systems grow in complexity, there is a need for control software engineering support. Soft-commissioning and reality in the loop (RIL) are two novel approaches which allow coupling simulation models to real world entities and allow the analyst to pre-commission and test the behavior of a system, before it is completely built in reality. To be flexible and fast in building up a simulation model fulfilling the requirements of soft-commissioning and RIL there is a need for a component-based modeling architecture. We define the characteristic requirements, and derive an architecture out of them, which is discussed from different aspects. Finally we briefly present a simple example.
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paper_title: Validation, off-line programming and optimisation of industrial control logic.

paper_content:

This article proposes a classification of different methods for validation, off-line programming and optimisation of control logic. The classification is an overview of different methods available and includes advantages and disadvantages for each method. The method overview points out a superior method, control system emulation, which is the most cost-effective and flexible method. The control system emulation method is also general and may be applied to validate and optimise control logic in various applications. Further, the method is compared with several other methods for validation of industrial control systems. However the method requires a standardised system architecture. This article proposes such architecture for the control system emulation method. Here, a control system emulator has also been implemented with the specific system architecture described in this article. An application case is also provided to demonstrate an approach to the integration of a control system emulator into a virtual manufacturing system.
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paper_title: An evolutionary approach for the industrial introduction of virtual commissioning

paper_content:

This contribution investigates the topic ldquovirtual commissioningrdquo from an industrial point of view and proposes an evolutionary and realistic technical concept for the introduction of virtual commissioning environments. Main points of this paper are the identification and formulation of industrial requirements for the introduction of a virtual commissioning environment, a proof of commercial tools against these requirements and a proposal of an evolutionary technical concept. Finally, this paper reports first experiences about a prototypical implementation of the proposed approach.
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paper_title: Economic application of virtual commissioning to mechatronic production systems

paper_content:

The interaction of heterogenous control hard and software plays a key role in enabling mechatronic production systems to become flexible and agile systems. Nevertheless, control software engineering still tends to be the last step within the development process. To a large extent it is carried out during the commissioning phase of the production ramp-up. On the first hand this leads to a loss of time and quality as well as to a loss of reputation and future orders on the second hand. A method that is referred to as Virtual Commissioning tries to overcome this situation. The aim is to enable control software engineering to, both take over the initiative in system design and to perform important activities earlier in the design process of production equipment. In this paper, the technological and economical scalability of Virtual Commissioning is analyzed. Based on the analysis, a technical concept for a scalable simulation environment is presented. The paper concludes with a new method for the economic application of Virtual Commissioning.
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paper_title: Towards realistic simulation of robotic workcells

paper_content:

In this paper a new approach to realistic simulation of robotic workcells in industrial manufacturing processes is presented, in which the workcell is composed of different classes of objects like robots, AGVs, conveyor-belts and sensors. The presented simulation system is directed to the areas of offline-programming and workcell layout. The novel approach described includes the embedding of an industrial robot controller into the simulation system by means of a versatile message-based interface and the use of a sophisticated environment model for intuitive simulation of grip and release operations, conveyor-belts and sensors. This is combined with a graphical 3D-visualization of the workcell in real-time and a windows-oriented interface based upon widely spread GUIs on PCs and UNIX-workstations. >
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paper_title: Systems approach to robotics and automation

paper_content:

Practical experiences in the development of modern robot control systems showed that the most successful components developed were those that were designed to work in comprehensive automation systems. These components were forced to be implemented in a greater framework and thus to adhere to standards and to standardized interfaces in order to facilitate integration and test of the final system. Although it was suspected in the beginning that system constraints in the form of architectural design guides imposed on the different parts of the realization might hamper the creativity of the developers, it was found that just the opposite was the case. After a training phase the developers managed to "think globally, but act locally", so that e.g. the development, the integration and the tests of a multirobot system for space-applications, a robot-simulation system, a flexible assembly-workcell and a new virtual-reality-system could be conducted in a coherent manner in a very short time.
---
paper_title: COSIMIR transport: modeling, simulation and emulation of modular carrier based transport systems

paper_content:

More and more industrial enterprises tend to validate their planning for new factories using simulation. Production environments often contain automated transport systems to move items between different work stations. We present a solution for modeling transport systems with respect to their interaction with all peripheries like robots and treatment machines. Modeling follows the process of mechanical assembly by putting together constructional components in 3-D space. Models of devices are of sufficient physical and electrical accuracy to test unmodified controller programs in a virtual commissioning phase to save time at the real start-up. In emulation, real controllers connect to the model to test and optimize control programs. In contrast to conventional discrete event simulation software, developers can play with the model during simulation to test its reaction and perform event of fault analysis. Simulation results are suited to secure design decisions of planners and reduce the risk of incorrect planning. Easy to recognize 3-D geometry and simulation interactivity qualify models for presentation and personnel training. Finally, simulation reveals suboptimal behavior and makes optimizations easier.
---
paper_title: AutomationML - the glue for seamless automation engineering

paper_content:

This contribution presents the basic architecture of the neutral data format AutomationML developed by the companies Daimler, ABB, Siemens, Rockwell, Kuka, Zuhlke, netAllied and the universities of Magdeburg and Karlsruhe. AutomationML serves for the data exchange between manufacturing engineering tools and therefore supports the interoperability between them. It covers information about the plant structure (topology and geometry) and the plant behaviour (logic and kinematics). The first version of AutomationML has been presented at the Hannover fair in 2008.
---

Title: Virtual Commissioning Of Manufacturing Systems: A Review And New Approaches For Simplification

Section 1: INTRODUCTION
Description 1: This section introduces the concept of manufacturing systems within the industrial environment and the challenges faced, leading up to the proposition of virtual commissioning (VC) as a solution to these issues.

Section 2: APPROACHES TO REALISING VC
Description 2: This section explores various approaches and configurations for achieving virtual commissioning, including historical context, different types of verification methods, and the current state of research and applications.

Section 3: GENERATION OF PLANT MODELS FOR VC
Description 3: This section investigates methodologies and challenges in generating simulation models necessary for virtual commissioning, with a focus on collaborative research efforts and tools used in the modelling process.

Section 4: CIROS
Description 4: This section elaborates on the capabilities of the CIROS® simulation tool and how it allows for high-level and low-level modelling, facilitating the virtual commissioning of manufacturing systems.

Section 5: Low-level Modelling
Description 5: This section discusses the steps and complexity involved in low-level modelling, including geometrical, functional, and electrical modelling tasks, which are crucial for creating accurate mechatronic component models.

Section 6: Geometrical Modelling
Description 6: This section describes the process of importing and structuring geometrical data from CAD systems as part of the initial step in creating simulation models for VC.

Section 7: Functional Modelling
Description 7: This section outlines the manual allocation of actuator and sensor functions to geometrical models to define integrated functional models during the simulation model building process.

Section 8: Electrical Modelling
Description 8: This section details the addition of electrical inputs and outputs to functional models, completing the creation of comprehensive mechatronic simulation models necessary for VC.

Section 9: NEW CONCEPTS FOR SIMPLIFIED VC OF MANUFACTURING SYSTEMS
Description 9: This section discusses the new approaches and concepts aimed at simplifying the virtual commissioning process, including leveraging CAE planning tools and the development of the Prototypical Engineering Modelling and Simulation Environment (PEMS).

Section 10: Test Bed Validation of the Concept
Description 10: This section outlines the validation process for the new VC approaches using a pilot manufacturing cell as a test bed, including the steps taken and the expected outcomes of the validation.

Section 11: SUMMARY AND FUTURE PROSPECTS
Description 11: This section summarizes the findings and potential future developments in the field of virtual commissioning, emphasizing the need for improved tools, standardized data formats, and cooperation between various stakeholders to advance the field.