Development and commissioning processes for machines and systems can be significantly accelerated with „digital twins“. Packaging technology companies also use simulation software.
Simulation software improves and accelerates development and production processes. During the ongoing operation of a system or during development, all process steps are synchronised in a so-called digital twin mapped. Any errors are analysed and eliminated in a continuous commissioning process. In the packaging industry, Bosch Packaging Technology, Krones and Somic, among others, have optimised their processes with simulation software from Munich-based „machineering GmbH & Co.KG“. After all, commissioning times can be reduced by up to 75 per cent and throughput times by up to 15 per cent.
Integrate simulation software from the very first idea
When planning new systems, the simulation software should be integrated into the planning process right from the initial idea. Development processes be integrated. The Munich-based company „machine engineering“ emphasises that its „industrialPhysics“ software is predestined to act as a cross-divisional platform. „IndustrialPhysics“ makes it possible to verify the current state of development at any time and to check its feasibility with other areas. The Specialist areas of mechanics, electrics and software can access the same models at the same time and edit them in their native development environments. Finally, the joint further development is immediately tested in interaction using the simulation.
This makes it easier for users to utilise „industrialPhysics“ by being integrated into more and more design and development software. It was only in December 2017 that „machineering“ announced that it would be cooperating with Solidpro GmbH in future. The Bechtle Group company provides „Solid Works“, a widely used CAD software tool.
Consistent development is ensured
Software-supported simulations are changing system development. Instead of taking one path when commissioning a system, as was often the case in the past, and then taking a step back and choosing an alternative solution in the event of a fault, a new approach is now taking place. Continuous commissioning takes place. All components of a machine are brought together and optimised in digital simulation media. This ensures the consistency of the development.
The simulation software also supports machine operators during operation. Systems can be simulated in real time. A „digital twin“ is created, so to speak. Digital twins are helpful for localising and rectifying any faults without long machine downtimes. Changes can also be simulated virtually in different variants before the most promising option is transferred to the real system.
„Machineering“ has developed the „machineering Digital Twin“ offers a simulation solution in which the digital twin is not installed in the company cloud. Instead, it runs as a separate virtual module based on real-time data directly in the control cabinet of a system. The digital twin provides all the data required for a smooth process during ongoing production operations. Even the calculation of complicated geometric models is possible without any problems.
Bosch Packaging Technology tests control software virtually
In the packaging sector, for example Bosch Packaging Technology on „industrialPhysics“. The machine manufacturer wanted to test its control software early on in the development process so that mechanical and electrical assembly would not be delayed by the late commissioning of the software. Now both development processes run in parallel. The software is tested with a „Hardware in the Loop“ module (HIL). „The HIL software test on the virtual machine, including the simulation of the product transport, is certainly the greatest benefit for us. This allows us to carry out tests on the control software at an early stage and react immediately if necessary,“ says Dominik Unger, responsible for simulation at Bosch Packaging Technology.
Krones uses „industrialPhysics“ in its own simulation tool
The packaging and filling specialist Krones AG optimised the commissioning times of its machines and systems in series production with the help of „industrialPhysics“. In product development, the software is used to test the PLC software even before the system prototype or control cabinet has been manufactured.
Krones even goes one step further: „We have developed our own tool with which we create our simulation models in the most efficient and effective way possible. We use various data sources and prepare them for ‚industrialPhysics‘ in a way that is suitable for simulation,“ says Andreas Jeziorowski, the developer at Krones responsible for engineering, development and the standardisation of virtual commissioning.
Somic is pleased about faster real commissioning
Since 2012, the packaging machine manufacturer has Somic GmbH & Co. KG relies on „industrialPhysics“. Commissioning is prepared virtually to such an extent that the real work at the customer's premises can later be carried out easily, quickly and safely. „We wanted to use simulation to significantly reduce the commissioning time by testing the program without the hardware, enable simultaneous program and machine optimisation and achieve an increase in quality in the project process,“ reports Eric Lah, Head of Electrical Design at Somic.
