Leverage Virtual Design to Build a Better System

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Leverage Virtual Design to Build a Better System


Agenda

Discussion

Concurrent development of electrical, mechanical, and control systems

Operator Training systems

Studio 5000® Logix Emulate™

Virtual Design


Virtual Design

Increases design productivity and reduce risk with virtual design

Machine Prototyping Throughput Analysis Virtual Commissioning Operator Training Systems

Easily design and build next

generation machines with

confidence

Optimize throughput with simple, real-time 3D simulation of

complex dynamic processes

Design, test, validate & commission production lines and new SKU’s before they are put

into service

Reduce risk and improve operations by training workforce

in a safe, virtual environment


Hardware in the Loop (HiL)

Simulation of an industrial process interacting with physical

Logix5000™ controller.

Software in the Loop (SiL)

Simulation of an industrial process interacting with a Studio

5000 Logix Emulate™ controller.

Virtual Design Overview

Pros: Requires no hardware, scalable with minimal costs, ability to

manipulate speed of clock, easily synchronize for real-time simulation

Cons: Performance can vary from physical hardware

Pros: Exact performance regards to scan times, same

instruction set executed

Cons: Can’t manipulate speed of clock, requires physical

hardware and space, costly to simulate large systems

EtherNet/IP or TCP/IP

or RSLinx OPC


Emulation vs. Simulation

Emulation: Imitation of behavior of an electronic system with the help of another type of electronic

system/computer

You emulate Controllers, I/O cards, servo drives, etc

Simulation: Imitation of behavior of the physical system with the help of a electronic system/computer

You simulate process changes and behaviors, mechanical systems & physical reactions, etc

Depending on the needs, both Emulation

and/or Simulation are necessaryStudio 5000 Virtual Design

Process Simulation

Equipment Simulation

Control System

Emulation


The Cost of Virtual Design (HIL vs SIL?)

Even though virtual design can help to reduce costs and

time to market, the level of fidelity strongly affects the

cost equation

Most systems can be simulated in parts or with a low

level of detail, making simulation viable and convenient

High fidelity fully virtual simulation for large systems

might not be economically viable

In many cases, the cost of the virtual design, although

high, is compensated and justified by savings in time and

other areas of the engineering solution

Cos

tLevel of FidelityBasic Realist

Level of SimulationParts System

HiL

SiL

Emulate

Risk

There’s a compromise between the level of

detail and the cost of virtual design


Agenda

Discussion




Virtual Design


Architect Logix Designer View DesignerApplication Code ManagerStudio 5000® Logix Emulate™


Logix Emulate?

Emulation of

Logix5000™ controllers

• Run and test application code without physical controllers and Input/Output (I/O)

• Provides advanced debugging to support code validation and virtual commissioning

• Control execution speed to identify potential issues

• Simulate discrete I/O

Emulation of

HMI applications

• Run and test FactoryTalk®

View SE/ME without having to connect to a physical controller

• 3rd party HMI applications also supported via RSLinx OPC

New! Logix Emulate for Operator Training

• Studio 5000 Logix Emulate™

for Operator Training provides the ability to interface with high fidelity process simulators and Operator Training Systems

• Snapshots, high speed data interface, scan and time control

What is

Simulate your system in a safe, virtual environment


Getting Started Is Easy Access is similar to a physical controller

Switch a project file between the emulator and a controller

Download the application to the emulator, just like you would for a physical controller

Emulate mimics the ControlLogix® chassis on a personal computer

Multiple controllers can be emulated on a single computer

A second emulated controller or 1789-SIM module can be used to simulate I/O

Data can be passed between controllers using produce / consume tags


Consistent User Experience If you can configure a Logix Controller, you can configure Studio 5000® Logix Emulate™

Look and feel mimics a ControlLogix® processor

Visualization of controller status

Run, Program and Remote modes supported via soft key-switch

and/or Studio 5000 Logix Designer®

Access configuration, properties and selections for:

Single Scan mode

Clear major faults


Code Troubleshooting SimplifiedBreak-Point / Trace-Point Capabilities

Trace-point (TPT) – Provides the trace information when the appropriate condition is detected

Break-point (BPT) – Provides trace information and halts the application execution

Instructions are executed with application logic and trigger the operation when the rung goes true


Configuring Studio 5000® Logix Emulate™

Simple, intuitive, easy-to-access configuration

Start, stop and adjust execution time

Configure tracing and when to

display the values

Access and display trace data

Configure time stamps

Access the trace log file location


Testing HMI ApplicationsSimulate Control Code and HMI Interaction all from a single PC

Step 1: Create Logix application and run in Studio 5000®

Logix Emulate™

Step 2: Create shortcut(s) in RSLinx® Enterprise for

the tags being tested.

Step 3: Map the HMI tag properties to the shortcut(s)

created and run the application to verify.


Agenda

Discussion




Virtual Design


Operator Training SystemsNew interface provides tight integration with Operator Training Systems

Enables powerful operator training capabilities by connecting an emulated control

system to high fidelity process simulators

• Create a safe classroom environment for operators to learn the system

• Enable more robust system testing to verify design and implementations before commissioning

• Prove out process and/or system design changes without impact to the running system

• Snapshot/Restore functionality enables the ability to restore process to an instant in time for situational training

• Data interface provides robust mechanism to inject simulated process control dynamics into the system

• Enables ability to halt/resume execution of the controller for pausing a process

3rd Party Operator Training Software

• Snapshot/Restore functionality enables the ability to restore process to an instant in time for situational training

• Data interface provides robust mechanism to inject simulated process control dynamics into the system

• Enables ability to halt/resume execution of the controller for pausing a process

MYNAH


Operator Training System Interface Reduce operator errors and identify control system errors before startup

Enables ability to halt/resume

execution of the controller for

pausing a process

Snapshot/Restore functionality

enables the ability to restore process

to an instant in time for situational

training

Also used for

pre-startup validation

Process Simulation Software

Emulated Controllers

New OTS

Controller

Ensure that your team is trained and prepared for the unexpected


How To Get Started on Integration OTS Vendor Integration Process

If you’re an OTS vendor and would like to get in touch with Rockwell Automation to establish an interface, please send an email to [email protected]

Rockwell Automation will establish an agreement with the vendor directly and provide the necessary software and information to get started

Current OTS Vendors that have established agreements with Rockwell Automation Logix Emulate for OTS are:

Please check our website: http://www.rockwellsoftware.com for additional information and vendors as they become available

Mynah – Mimic Andritz – Ideas Schneider - SimSci DYNSIM

Cape – VPLink Honeywell – Unisim

mailto:[email protected]

http://www.rockwellsoftware.com/


Agenda

Discussion




Virtual Design


Automation Productivity – Virtual DesignEngineering Cycle reduction from Computer Aided Engineering to a functioning plant

Solidworks / Inventor / … for design

IndustrialPhysics for machine and Hardware In the Loop (HIL) simulation

HoloLens for visualization

Studio 5000® LogixEmulate™ for developing Machine Controller application code

Logix Control Systems on EtherNet/IP.


VIDEO DEMO…


Agenda

Discussion




Virtual Design


Virtual Design

Increases design productivity and reduce risk with virtual design

Machine Prototyping Throughput Analysis Virtual Commissioning Operator Training Systems

Easily design and build next

generation machines with

confidence

Optimize throughput with simple, real-time 3D simulation of

complex dynamic processes

Design, test, validate & commission production lines and new SKU’s before they are put

into service

Reduce risk and improve operations by training workforce

in a safe, virtual environment


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Leverage Virtual Design to Build a Better System

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