Design and operate systems and processes virtually
With WinMOD, you can create your complete automation system in virtual space.
down to the smallest detail.
Virtual commissioning
Test control programmes safely and quickly before they are transferred to the real system.
Virtual operation
Carry out service processes independently of the location of the machine/system and prepare optimisations during ongoing operation.
Virtual machine / system
Creation of functional 3D images of real machines that can be connected and put into operation without changing the software.
Virtual commissioning
Virtual modelling and operation of systems
Virtual commissioning (VIBN)
According to current practice, virtual commissioning (VIBN) corresponds to real commissioning with a virtual machine or system. The connected automation system can be real (HIL) or virtual (SIL).
In practice, several different contents are mixed up during the commissioning of a real system.
- Subsequent clarification of the actual functionality of components and systems
- Continuation of software development during commissioning
- Functional test of the software with the real system
- Parameterisation and optimisation of the automation software with the real system
- Instruction of the operator and service personnel
This work content is very indefinite. They are costly because they take place on site, they are risky and they can drastically delay planned commissioning dates.
The innovative alternative is virtual commissioning (VIBN). In terms of content, it is a real commissioning of the real control system and the original software in conjunction with a virtual machine/system. The virtual machine/system has sufficiently identical behaviour to the control system to be able to put it into operation. The work content of commissioning can thus be carried out together with the project participants, regardless of the location and state of completion.
Virtual operation
Once the real machine/system has been commissioned, the virtual machine/system is available for further use.
Service processes can be supported regardless of the location of the machine/system and optimisations can be prepared during operation.
Digital twin or shadow system
If a real or virtual automation system is operated in conjunction with a virtual system permanently in parallel with the real system, this is referred to as a digital twin or a „shadow system“. During operation of the systems, optimisations or process changes can be prepared without downtime and without endangering the real system. Particular attention should be paid to the constant adaptation of the shadow system to the structure and behaviour of the real system. This enables a constant comparison between real and virtual behaviour.
The digital twin supports the implementation of migrations. This applies in particular to the replacement of automation systems with extreme requirements for recommissioning while the system is in operation.
Virtual machine / system
The virtualisation of machines and systems is a deepening and expansion of system simulation.
The result is a model that corresponds to reality in terms of behaviour and communication to such an extent that it can be connected to a real automation system and put into operation without any software changes.
Virtualisation of machines and systems
The WinMOD system platform has been prepared for these goals since 1991. The first prototype for a virtual machine tool was created in 2002. In 2005, the virtual system was part of a specification for the VIBN of a production cell in the automotive industry.
Virtualisation itself already creates an initial benefit. A functional specification is created from the point of view of the automation engineer. Defects and errors are recognised and rectified at an early stage. A communication platform is available for all subsequent uses, which is recognised and understood in the same way by everyone involved.
The virtual machines/plants are created in the WinMOD project from the engineering data of the upstream or parallel engineering processes and must be kept consistent with them.
Virtualisation in process automation
For virtualisation in process automation, the WinMOD system platform has been gradually expanded to include industry- and technology-specific libraries with which the necessary simulation depth for holistic modelling can be achieved. WinMOD communications for integration in a runtime system are used for collaboration with specialised simulation tools.
Virtualisation in factory automation
For virtualisation in factory automation, the WinMOD system platform has been expanded to include the system modules for WinMOD-SIMLINE with 3D visualisation and the technology libraries with material flow capability. This allows machines and systems to be virtualised for all uses from an automation perspective.