b07 - Process Simulate Virtual Commissioning

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
Shop-floor challenges
Tool change procedure Throughput reaction Conveyor optimization
Sensor positioning
Electrical device signals Handling variants
Safety procedures
HMI synch with tools
Page 2
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
Page 3
Story board
OEM XYZ Supplier 123
+
Page 4
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
Page 5
EBZ Case Study
https://sales.industrysoftware.automation.siemens.com/accesscount/188 28/EBZ-Group-Customer-Testimonial-R7T1A1
Page 6
Primary Line Builder Challenge
Validate OEM changes faster and more accurately
Page 7
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
Page 8
Tool design Example
Page 9
OEM instructions
OEM XYZ Supplier 123
Page 10
The Use Case: Requirements

Peripheral Resources
Safety
Variants Synchronization Native Language OEM Standards Maintenance
Traditional Work cell Simulation

Page 11
Robotics engineers tasks

Manage changes after receiving a new path: Variant Branching Synchronize robots to PLC OEM Standard Robot Code Download programs and test
Page 12
Robotic Simulation
Page 13
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
Event-based
OP 1 A NOT A
Page 14
OP 2 OP 3
OP 2
OP 3
Supplier Analyze: What is required?
Tooling Clamps and Pose sensors address new variant Robotics OEM Standard program considers pedestal gun and new variant
Page 15
Control virtual commissioning
Mechanical
Kinematics Robot Programs Mechanical Sequences Layout Clearances Cycle Time
Electrical
Inputs / Outputs Logic Interlocks HMI Diagnostics Safety
Evaluate Mechanical and Automation System behavior

Page 16
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

Page 17
VC Environment
Process Knowledge Simulation Digital Process Design Automation Validation
Signal Mapping
Real Time Signal Exchange
OPC (Client & Server)

Controls PLC Code
PLC
Page 18
HMI
Virtual Commissioning Demo
Page 19
Life Cycle Processes

(Current State) Estimating Planning Design Construction
Process Planning & Documentation
Controls Design
Workcell Simulation
Equipment Design Program Robots
Installation
Debug
Try-Out
Cost and Time
Page 20
Life Cycle Processes

(Future State) Estimating Planning Design Construction
Process Planning & Documentation
Controls Design Workcell Simulation

(Enhanced)
Debug OLP (Enhanced)
Equipment Design Debug

(Physical)
Installation
Try-Out
Cost and Time
Page 21
AMT Testemonial
https://sales.industrysoftware.automation.siemens.com/accesscount/24847/Virt ual-Commissioning-Video-AMT-Testimonials-R7T4N3
Page 22
Benefits
Estimating Planning Design Construction
OEM
Earlier
start of production Lower cost on changes

Major Risk
Tier 1 Primary LB
reduction: Mature processes Right the first time Standardization of processes and components
Collaborative
Tier 2 Eng Houses
and Efficient Engineering Validation reduces risks on site
Page 23
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
Page 24
THANK YOU!
Page 25

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Process Simulate Virtual Commissioning

Shay Shomroni Director Industry Solutions Manufacturing Business Group shay.shomroni@siemens.com

Siemens PLM Software

Tool change procedure Throughput reaction Conveyor optimization

Electrical device signals Handling variants

HMI synch with tools

Siemens PLM Software

Siemens PLM Software

Siemens PLM Software

Supplier Analyze: What is required?

Siemens PLM Software

EBZ Case Study

Siemens PLM Software

Primary Line Builder Challenge

Validate OEM changes faster and more accurately

Siemens PLM Software

Siemens PLM Software

Tool design Example

Siemens PLM Software

Siemens PLM Software

The Use Case: Requirements

Variants Synchronization Native Language OEM Standards Maintenance

Traditional Work cell Simulation

Siemens PLM Software

Robotics engineers tasks

Siemens PLM Software

Siemens PLM Software

Siemens PLM Software

Supplier Analyze: What is required?

Siemens PLM Software

Control virtual commissioning

Evaluate Mechanical and Automation System behavior

Siemens PLM Software

Dont disturb production

Siemens PLM Software

Real Time Signal Exchange

OPC (Client & Server)

Siemens PLM Software

Virtual Commissioning Demo

Siemens PLM Software

Life Cycle Processes

Process Planning & Documentation

Equipment Design Program Robots

Cost and Time

Siemens PLM Software

Life Cycle Processes

Process Planning & Documentation

Controls Design Workcell Simulation

Debug OLP (Enhanced)

Equipment Design Debug

Cost and Time

Siemens PLM Software

Siemens PLM Software

start of production Lower cost on changes

Tier 2 Eng Houses

and Efficient Engineering Validation reduces risks on site

Siemens PLM Software

Process Simulate Take Aways Highly functional & easy to use

Widely deployed by OEMs and LB

Siemens PLM Software

Siemens PLM Software

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