Multicore simulation in real time

Virtual models for the simulation environment are created from real components and assemblies. © ISG

The real-time calculation of complex simulation models is made possible by parallelization. The module-based system model is broken down into various sub-models - automated by the system or manually by the user. Parallel computing cores make it possible to significantly accelerate the overall model calculation. Even the most complex systems can be mapped. This includes the description of the respective process, the simulation of the machine behavior, for example with regard to logic, kinematics and dynamics, as well as the behavior simulation of industrial control components including their sensors and actuators. The modeling environment shows how the overall model is distributed across the individual computing cores and allows adjustments and reconfigurations to be made. The platform is therefore the basis for functional solutions that allow different models to be combined with each other, regardless of whether they are SILS or HILS models.

Open library concept for the integration of models

A simulation platform offers the greatest added value for the user if it has standardized integration interfaces for incorporating third-party simulation models. Specific libraries can be seamlessly integrated into simulation solutions via these integration interfaces. This gives machine builders the opportunity to simulate the hardware and software components of a system end-to-end without system discontinuity, right through to the virtual commissioning of entire factories. The modular library is growing continuously and provides ready-made partial models for direct integration into a wide range of application scenarios. This not only reduces the necessary modeling times, but also increases the informative value of virtual commissioning, as ready-made models from simulation and component experts ideally depict reality. The open library concept also offers plant and machine manufacturers new opportunities if they provide the plant operator with the simulation model of their production plant. Four business opportunities are outlined below.

1. training of the operating personnel

It is already common practice for machine manufacturers to provide plant operators with the digital twin so that they can use it to train their staff. The advantages are obvious: critical situations can be simulated on the computer that cannot be caused in reality, even for training purposes, for safety reasons or because production has to continue. With training in the virtual world, however, operators can prepare themselves well for an emergency so that they can react correctly and restart the system as quickly as possible. The training also increases the productivity of the system - after all, the system operator can get started immediately after the real commissioning of the machine without first having to complete an "operator crash course" and block the system in the process.

2. predictive maintenance service

Systems require regular maintenance. This is usually carried out by the machine manufacturer or a specialized service provider. With a digital twin of the system and the additional use of a predictive maintenance tool, maintenance companies can offer customers predictive maintenance as an additional service. This involves recognizing when a problem is just beginning to develop. The virtual system serves as a "golden reference" - if the parameters of the real system deviate from this, intervention may be necessary. The underlying predictive analytics model takes into account the current operating data as well as process engineering correlations and relevant influencing factors of the plant periphery. By comparing this with historical data, e.g. using an integrated AI solution, it is possible to determine how the data is most likely to develop, allowing countermeasures to be taken before damage occurs. Another business model based on predictive maintenance is that the service provider is not remunerated for the maintenance measures, but for guaranteed system availability. It is then up to the service provider to keep the machine in good working order.

3. compass for the best technical solution

Today, there are hardly any off-the-shelf machines. The rule is rather customized individual production. This is where the difficulty often lies for the customer - what is the optimum solution for them? The plant manufacturer can carry out a pre-project with the customer before the quotation phase, in which they run through various configurations on the simulation platform. The more digital components are already available in the libraries, the less effort is required. It is also to be expected that the buyer will then also commission this machine manufacturer to implement the system.

4. digital retrofitting

Instead of building from scratch, in many cases it is worth modernizing existing systems by replacing obsolete components or retrofitting them for a new product. Similar to the engineering of a new development, the effort involved can be significantly reduced if the operator first carries out the retrofitting virtually on the simulation platform. The prerequisite for this is that the plant manufacturer provides him with the digital twins and simulation models for a fee.

Location-independent access, redundancy and knowledge transfer

An open and multicore-capable simulation platform enables co-simulations in real time. On the one hand, designers can carry out extensive test runs with different virtual control systems in order to find the optimum control system for the respective system with relatively little effort and in a short time. On the other hand, an entire system can now be simulated end-to-end and thus put into virtual operation. The platform should contain expandable simulation libraries that also allow highly specialized, technology-specific third-party simulation solutions to be integrated via appropriate interfaces. It has also been shown that a shared online platform that grows with the company is very crisis-proof. The keywords here are location-independent access, redundancy and knowledge transfer. Plant manufacturers are also offered new sources of revenue - through the provision of digital twins, simulation models and services such as predictive maintenance.

Dr. Christian Daniel, Business Manager Simulation Technology and Dr. Christian Scheifele, Head of R&D Simulation Technology, both ISG Industrial Control Technology