Lüdemann-Ravit, Bernd
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The increasing use of simulation technologies, especially virtual commissioning, in the context of modern plant development for manufacturing discrete parts is driven by the pressure to shorten time-to-market cycles and overcome supply bottlenecks. The need for robust technologies to seamlessly integrate the digital and physical world is growing as machine data becomes more readily available. A challenge to this integration is presented by the need to continuously adjust the movement parameters, especially for event-discrete actuators based on live data, taking wear, ageing and process-time fluctuations into account. A lack of synchronization leads to discrepancies between the simulation and reality renders them useless. Related works in this field are discussed, which highlight the complexities of achieving synchronization between simulation and reality, particularly in event-discrete signals and systems. The aim of this article is to present a method for reusing virtual commissioning models for operation-synchronized simulations at actuator level. This approach includes introducing of a methodology called prescheduling in order to compensate process uncertainties and also defines the necessary requirements for the simulation tool and model. The method is validated using an industrial test system and a commercial virtual commissioning tool to confirm ist suitability for real-life implementation in industrial plants, which suggests its suitability for improving production efficiency and reducing costs by means of machine monitoring and proactive control interventions.
Das Industrial Metaverse scheint der nächste große Game Changer in der modernen Industrie zu werden und wird diese signifikant verändern. Die Vision ist nicht nur die Simulation einer einzelnen Anlage, wie sie Unternehmen heute beispielsweise bei der virtuellen Inbetriebnahme einsetzen, sondern ganzheitlicher Anlagenverbunde aus heterogenen Maschinen samt Fabrikperipherie und Infrastruktur – einer Digitalen Fabrik. Um das Industrial Metaverse zum Leben zu erwecken, wird eine Vielzahl zusätzlicher Technologien und Innovationen benötigt, als lediglich Digitale Zwillinge. Dieser Beitrag schlägt eine ganzheitliche Referenzarchitektur eines Industrial Metaverse vor und fokussiert auf dessen Nutzen.
Various software environments have been developed in the past to create digital twins of single cells or a digital twin of a factory. Each environment has its own strengths and weaknesses and has been designed with a specific focus. The environments that are able to holistically simulate complete factories are limited in terms of the modelling details required for the analysis of single manufacturing cells (e.g., manufacturer-independence of the individual digital twins) and their ability for virtual commissioning. This paper presents three options for realising a virtual commissioning of linked cells using a 3D integration platform with NVIDIA Omniverse, consisting of two different digital models fused into a combined model, also representing material flow. First, with a source/sink solution and unidirectional connector controlled by OPC UA; secondly, with a bidirectional connector, developed in the course of this elaboration, and an extension of the 3D integration platform controlled by Apache Kafka; thirdly, with a bidirectional connector and using only an extension of the 3D integration platform. The research demonstrates that virtually commissioning multiple linked digital twins from different manufacturers in a 3D platform with material flow makes a significant contribution to the industrial metaverse.
Das Forschungsprojekt TwinMaP hat zum Ziel, eine effiziente Komplettbearbeitung von Bauteilen variabler Losgrößen in einem heterogenen Maschinenpark zu ermöglichen. Der wirtschaftlichste Produktionsablauf soll mittels digitalen Zwillingen, die mit den realen Anlagen und einer Integrationsplattform vernetzt sind, in einer Vorsimulation ermittelt werden.
Die Fertigungsindustrie orientiert sich derzeit in Richtung von Technologien, die Sprungbrettinnovationen in der Produktion ermöglichen. In diesem Zusammenhang werden häufig das Industrial Metaverse und die Künstliche Intelligenz (KI) genannt. In diesem Artikel werden erste Implementierungen dieser Technologien und aktuelle Forschungsaktivitäten im Produktionsumfeld vorgestellt.
The Industrial Metaverse (IM) is an upcoming topic for companies and offers new possibilities to digitalize and optimize their business processes together with AI capabilities. In the production domain, the Industrial Metaverse is a step towards the vision of predicting factory behavior for optimization purposes. A central challenge is a complete factory model necessary as the base to predict its behavior. Therefore, the IM approach is promising to build and contain this model out of available single Digital Twins of factory parts. Consequently, an IT target landscape is required to build an Industrial Metaverse for Digital Twins. This paper evaluates different design pattern options for an industrial IT architecture reference implementation of an IM that companies can use in current IT landscapes. It also proposes a high-level roadmap towards the proposed target IT architecture of an IM.
In general, current systems for the Digital Factory implement a product-process-resource (PPR) data model in a monolithic rich-client/server architecture with a single database persistence layer. Common data objects are the product bills of material, descriptions of the production processes, or the resource structure, e.g. bill of equipment. The main drawback of the current monolithic architecture is the slow rate of development, which prevents fast adoption of the software to the new production planning process (i.e., due to new technologies for the transformation of the automotive industry with the goal of electrification) is not possible. Furthermore, time-consuming and error-prone export-import operations characterize the collaboration of the engineering supply chain. Mercedes-Benz has created a new IT system architecture for their Digital Factory. The core idea of this architecture is a module-based approach. Each planning step has its own module, e.g. product analysis, layout planning or cost calculation. One single module consists of a server-based business logic, a web-based user interface and its own database. Each module is the source of master data objects that originate from the corresponding planning step and refers to data objects from predecessor planning steps. The single modules communicate mostly via KAFKA. The usage of a model based application engine allows the fast creation of different modules. Best-of-breed third-party systems for specific planning steps can be integrated into the system architecture. Web technologies allow suppliers to access the Mercedes-Benz systems directly for a fully integrated supplier collaboration. Roll-out has started and has already led to significant efficiencies.