Taking the pressure out of the boiler

Things are usually very hectic at the end of a plant construction project. Commissioning engineers are under immense pressure, which can lead to acute or long-term health problems. Stressed employees also make more mistakes. However, if they can bring forward some of their work tasks by virtually commissioning and testing the production system to be delivered, the situation on the construction site will be considerably less stressful later on. It also gives those responsible the opportunity to test the (virtual) system much more extensively and intensively - with correspondingly positive effects on quality. In addition, employees do not have to be on site in the early project phase, but can work in the office or from home. Noise pollution is much lower there than on the construction site. They can concentrate on their tasks without being repeatedly disturbed by queries.

Teamwork made easy

Thanks to the earlier exchange of information between the various disciplines - mechanical, electrical and software - coordination is more structured and inaccuracies of fit or misunderstandings can be identified and rectified more quickly. However, a simulation model is also a very effective means of communication for collaboration with the customer: plant engineers and the subsequent operator can iteratively test their ideas and suggestions on the model and inspire each other. An exchange of knowledge takes place en passant, which is beneficial for everyone involved.

Secure the system configuration

Thanks to the VIBN, the safety assessment takes place at a very early stage and countermeasures can be taken if necessary. As a rule of thumb, the cost of errors increases tenfold in each subsequent project phase. Conversely, these costs can be significantly reduced the earlier a fault is rectified. This makes in-house production more efficient in terms of costs and throughput time, while the customer benefits from increased process quality.

VIBN - more than just part of the product life cycle

A VIBN also offers enormous advantages outside of the actual construction of a system - from conception to go-live.

For distribution:

The sales engineer does not have to refer to material from an existing system that very probably does not correspond to what the current customer wants. Instead, he shows him a moving, already customized 3D model and can even run through different designs with him.

In service and in research & development:

The VIBN is also used for existing systems to test alternative scenarios in terms of their feasibility, cost effects and process optimization. The time-to-market for new developments is significantly reduced.

In training and further education:

New employees can be trained in a very practical way - on digital systems whose counterparts exist in real life. The digital twin can also be used to train operating personnel and for training purposes.

The online component library that grows with you

Many standard components are used in mechanical and plant engineering. As a rule, 80 to 90 percent of even special systems can be built from available modules. Once the digital twin is available, it can be used again and again. Future users also have the security of knowing that these are tried and tested units. The savings potential in terms of both time and money is even greater if several plant manufacturers and component suppliers share their virtual components.

The easiest way to do this is via the platform-based, modular TwinStore online component library, which can be continuously expanded. It grows with each new digital twin and provides ready-made partial models for direct integration into a wide range of application scenarios. This reduces modeling times. The informative value of virtual commissioning is also increased, as the models of existing components and systems ideally reflect reality. As an online platform, access is possible from anywhere and at any time. At the same time, plant manufacturers are offered new sources of revenue - through the provision of digital twins or simulation models and services such as predictive maintenance.

Simulation technology as part of value creation

The VIBN incurs one-off financial outlay for hardware and software equipment. In addition, there are project-related expenses for in-house personnel or service providers who create the simulation models and configure the individual tests of the virtual IBN. However, the expenses for carrying out the VIBN itself are not additional costs, as they compensate for later expenses in the real IBN. Ideally, the VIBN-specific costs have already been amortized after the first system is started up. However, maximum efficiency gains are achieved by reusing the digital components and the simulation models, which also have a modular structure. However, the virtual control system should not be part of the simulation, but connected via an interface. The consistency of the simulation methods used is crucial - from model-in-the-loop to software-in-the-loop and hardware-in-the-loop. It is often the case, for example, that the designers are not yet able to assess which drive technology is best suited at the start of the project. This is why they initially work with various simulation models, which they later replace with the digital twin.

Win-win-win situation for component suppliers, plant manufacturers and operators

A VIBN integrated into the digital value chain pays off for everyone involved: In addition to time savings and immense cost savings, the benefits include improved quality of the production systems, their rapid adaptability and new possibilities for plant and process optimization. Other benefits include practical training and reduced time-to-market.

Dr. Christian Daniel, Business Manager Simulation Technology, ISG Industrial Control Technology

Guide "Virtual commissioning

In order to support the German mechanical and plant engineering industry with regard to VIBN, the VDMA and its partners have produced the guide "Virtual commissioning - Guidelines for cost-effective introduction". It is available for download here.