Step by step to the real system

This is because different modules and components often come from different manufacturers. This can lead to delays in delivery and impair the efficiency of commissioning. One approach to solving this problem is hybrid commissioning (HIBN), in which virtual and physical commissioning are combined. HIBN should make it possible to gradually replace the virtual components with physical ones, starting from virtual commissioning, without changing the control configuration. This creates a hybrid system configuration that contains both virtual and physical components. It makes it possible to commission the physical system step by step, while the function of the system is monitored in the virtual environment - as was previously the case with virtual commissioning. The prerequisite for this is a simulation-capable system model. The technical concept envisages a gateway as the link between the control system, the simulation and the physical components. It establishes communication between the control system and the virtual and physical components and performs the tasks of a network switch. In contrast to a conventional network switch, the gateway has a special feature - it forwards the fieldbus telegrams sent by the controller to both the virtual and physical components. The telegrams from the components are merged and all information is bundled into one telegram that is sent to the controller. This ensures smooth interaction between all the components involved.

Testing virtual and physical interaction

A prototype implementation of the HIBN concept is being carried out at the ISW of the University of Stuttgart to demonstrate its technical feasibility. Among other things, the Profinet fieldbus protocol is used as an example to test the interaction of virtual and physical components. The tests are carried out on a sample system with industrial components; it provides a realistic environment for testing the functionality and effectiveness of the HIBN in practice. The experiments deal with different configurations of hybrid commissioning; the concept is applied to one conveyor belt, the entire conveyor belt system and the entire plant without physical unit loads. This will provide insights into how HIBN can be applied in different industrial contexts and what technical challenges need to be overcome. The results contribute to a deeper understanding of the potentials and limitations of HIBN and provide a basis for future research and development activities in this field.

Advantages of hybrid commissioning

Several advantages of HIBN over purely virtual or physical approaches can be identified in the experiments. For example, the use of virtual representations makes it easier to compensate for delays in the delivery of individual physical components. Comprehensive pre-commissioning of modules is possible, as the physical module is inserted into the virtual plant and the overall performance of the plant can be tested in advance. HIBN can also reduce the cost of functional testing by replacing the physical material flow with a virtual one; more thorough testing leads to higher quality control software. HIBN is suitable for industries with complex, material flow-intensive production facilities. The areas of application range from individual physical components to complete systems.

With the increasing use of virtual commissioning and the associated growing availability of simulation models, it is to be expected that the importance of HIBN will continue to increase in the future.