Realising the open virtual commissioning of modular automation systems

To address the challenges in the automotive industry posed by the need to rapidly manufacture more product variants, and the resultant need for more adaptable production systems, radical changes are now required in the way in which such systems are developed and implemented. In this context, two enabling approaches for achieving more agile manufacturing, namely modular automation systems and virtual commissioning, are briefly reviewed in this contribution. Ongoing research conducted at Loughborough University which aims to provide a modular approach to automation systems design coupled with a virtual engineering toolset for the (re)configuration of such manufacturing automation systems is reported. The problems faced in the virtual commissioning of modular automation systems are outlined. AutomationML - an emerging neutral data format which has potential to address integration problems is discussed. The paper proposes and illustrates a collaborative framework in which AutomationML is adopted for the data exchange and data representation of related models to enable efficient open virtual prototype construction and virtual commissioning of modular automation systems. A case study is provided to show how to create the data model based on AutomationML for describing a modular automation system

Special Session on Industry 4.0

No abstract available

Error handling within highly automated automotive industry: Current practice and research needs

Fault tolerant systems, commonly found in literature, are implemented in various computer applications. Some of these methods have been studied and developed to aid manufacturing systems; however, they have rarely been integrated into the manufacturing process. Broadly, the problem seems to be integration of error handling procedures towards the end of physically building the manufacturing line, lack of a defined workflow, untested program logic and inadequately equipped personnel to name a few. To this end, a survey was conducted within the Swedish automotive industry to get an understanding of current error handling procedures and its shortcomings, and are presented here. Based on this data, and looking at the trends within the manufacturing industry, this paper also identifies research topics aimed towards defining methods to create next generation fault tolerant manufacturing systems

Implementation of Digital Twin-based Virtual Commissioning in Machine Tool Manufacturing

Virtual commissioning is not a new concept; However, it is all the rage with the introduction of Industry 4.0, in the field of product lifecycle management, computer-aided design (CAD), computer-aided manufacturing (CAM), and within the industrial automation programming frameworks. Although, this is a very active area of research and innovation, these technologies have little implementation in the machine tool industry [11]. There is still no integrated simulation environment for virtual commissioning in the market. In this context, digitalisation is a key driver. The aim of this paper is to describe the practice of virtual commissioning in the machine tool manufacturing industry by identifying available solutions in the market and addressing the challenges faced within the machine tool sector. As a result, a digital twin based virtual commissioning solution has been developed at Danobatgroup, the leading machine tool builder in Spain, which is a step forward towards the digitalisation of machine tool manufacturing

Virtuelle Inbetriebnahme und die Nutzung von Extended Reality und Automatisiertem Testen: eine Umfrage in der Industrie

Virtual Commissioning (VC) is seen as an important technology for managing the complexity of production systems. While it is demonstrated that VC can reduce commissioning time, defect rates and costs, the rate of industrial adoption is below expectations. In this paper, we present the results of a survey conducted to investigate the use, expectations, and barriers to the use of VC with an additional focus on Virtual Reality (VR), Augmented Reality (AR) and Test Automation (TA) in this context. The survey results reveal that just over half of the respondents use VC, albeit rarely to occasionally. Barriers to the use of VC are not technological. VR and AR technologies are used in many companies, but not frequently. The results indicate that the potential benefits of using these technologies are not clear enough to justify further investment in what is seen as a somewhat immature technology. TA can only be found in large companies. The main barriers are the amount of effort required to create and maintain automated tests and a general lack of know-how and resources. Respondents agree that all three technologies will become more important in the future

Validating a reconfigurable assembly system utilizing virtual commissioning

Published ArticleSouth African manufacturing companies today need to be more sophisticated technologically to compete for global markets. The latest trend in automation and manufacturing emerges in the form of reconfigurable systems. The aim of this paper is to show the development of a reconfigurable assembly system and using virtual commissioning to plan, validate and optimize it. To achieve this "DELMIA" software was used to create a virtual simulation environment to verify an assembly cell from such a system as a case study. Simulations were conducted to verify software functions, device movements and operations, and the control software of the system. As a result, it was found that virtual commissioning is an excellent tool for predicting how the system will function, verifying system code early, and rectifying design flaws. This will enable manufacturing companies to be more competitive, ensure increased productivity, save time and ensure them an advantage over their competition