Virtual commissioning when converting an existing system
PIA Fact Check
- System downtime reduced from 9 to 4 weeks
- Cycle time reduction from 120s to 60s
Virtual commissioning - digital twin of a production line
Virtual commissioning is an innovative tool that makes it possible to model digital twins of complex systems and to test and optimize their functions virtually. This method provides a precise picture of the real processes of a planned system even before the first machine part is installed. At PIA Automation, specialists have been using lead simulation for years.
Conversion of an existing system
The project involved the conversion of an existing system, which was not achieving the desired output due to changed boundary conditions. PIA analyzed the problems and suggested reprogramming the system. By modeling the modified system as a digital twin, the new programming could be tested virtually, which reduced the downtime of the system from nine to four weeks and saved the customer over 50% in time.
Construction of a digital twin
The design of a digital twin begins with a hand-drawn sketch, which is transferred to a 3D model. After the design is finalized, a kinematic model of the machine is created, which includes all moving parts, sensors, and the material flow. A behavioral model is then programmed for the individual field devices that simulates the specific functions of the machine.
Advantages of virtual commissioning
Virtual commissioning offers numerous advantages, including high software quality at an early stage of development, the avoidance of errors and bad investments as well as significant time and cost savings. Customers have the opportunity to get to know their system much earlier and save on prototype components.
Attractiveness for customers
PIA Automation offers a very high level of detail and simulations that can be transferred 1:1 to the real system. The PLC and robot controller emulations correspond to the real programs down to the last detail and can be adopted directly. Existing customer software can be used flexibly. This means that system design, programming, and commissioning are all possible from a single source.
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