This offers automation and process engineers new opportunities to use simulations to improve the design, use and performance of industrial processes.

The Studio 5000 simulation interface connects Rockwell Automation's industrial control systems with simulation and modeling tools. The latest version of the tool extends this connectivity to Ansys Twin Builder, a leading software for creating simulation-based digital twins or digital replicas of physical plants. The software uses multiphysics to determine how real-world elements such as flow rates, mechanical loads and thermal profiles can affect the performance and condition of equipment.

"By connecting a control system to Ansys Twin Builder, users can simulate complex physical processes and input realistic values into the control system," explains Julie Robinson, Business Manager at Rockwell Automation. "This can provide far-reaching insights throughout the entire product lifecycle. For example, running a simulation model in parallel with a physical system during production provides opportunities to optimize performance in real time."

Engineers can use digital twins and simulations to improve system design, deployment and performance:

• Creating and testing device designs in a virtual environment saves development time and reduces the need to build costly physical prototypes.
  
  
• Virtual commissioning of devices helps avoid unpleasant surprises during commissioning at production sites.
  
  
• Compare simulated and actual system performance to identify adjustments that can optimize efficiency, performance and more.
  
  
• Test process changes in a virtual environment before making them on a physical system to optimize throughput or other performance aspects.
  
  
• Calculating the remaining life cycle of components so that they can be replaced as part of a predictive maintenance strategy before unplanned downtime can occur.
  
  
• User training in a virtual environment where equipment availability is not an issue and users can be trained in unusual or dangerous scenarios.

"Connecting the digital and physical worlds with the Studio 5000 simulation interface creates tremendous value for users," explains Shane Emswiler, Senior Vice President of Products at Ansys. "It can help them go from concept to finished device faster and more cost-effectively, and provide useful new insights during production. For example, users can use what-if scenarios to understand the impact of changes on a process. Users can also create virtual sensors to determine values that would otherwise be too expensive or impossible to obtain. They can also predict failures that will have a negative impact on the bottom line."

The Studio 5000 simulation interface allows a digital twin to be connected to an emulated or physical control system. Connecting to an emulated control system can help users optimize production in the design phase before they have a physical control system or equipment available. By connecting to a physical control system, they can create a digital twin of the equipment and compare it to the actual performance.