SY07 - Leverage Virtual Design to Build a Better System

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Virtual DesignLeveraging Virtual Design to Build a Better System


Agenda

Operator Training Systems

Virtual Design

Collaborative Engineering

Studio 5000 Overview


Typical Workflow of an Automation Project

Create P&ID

Create basic mechanical

model

Import system

configuration from P&ID

or CAD

Define System needs

Design Alarms model

Create organizational

model

Create system libraries

Control document

revisions

Validate system design

Simulate critical

processes

Use library to create

basic simulation

Refine system needs

Select devices

Generate RFQ

Generate BOM

Validate BOM

Create HW configuration

from CAD, P&ID & BOM

Create application &

data structure from CAD,

P&ID & BOM

Address application

specific needs

Configure Alarms model

Configure data model

Use organizational

model to build

application and data

structures

Configure, deploy and

manage devices

Deploy visualization and

control object instances

from library

Update library with

changes

Control document

revisions

Validate System

configuration (FAT)

Synchronize changes to

P&ID, Electrical CAD

and Mechanical CAD

Validate system

deployment (SAT)

Configure, diagnose and

manage devices

Diagnose system health

& identify issues

Optimize application

Optimize alarms

Deploy data access

needs (Historian,

Production monitoring,

etc)

Control document

revisions

Control system changes

Update changes to

P&ID, Electrical CAD

and Mechanical CAD

Manage alarms

Monitor Production

Diagnose and maintain

devices

Control system changes

Update library with

changes

Control document

revisions

Maintain system

revisions

Monitor system

Identify improvement

opportunities

Simulate proposed

improvements

Evaluate installed base

Leverage existing

engineering for design

Design ProcureConfigure &

BuildInstall &

CommissionOperate & Maintain

Optimize & Upgrade


Smarter. More Productive. More Secure.

INTEGRATEDARCHITECTURE

Multidiscipline Control

Industrial Automation Security

Protect Automation Investment

Operations Management

Scalable Industrial Hardware

Automation Design Productivity

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Session

Focus


Desig

n T

ime

PDM/PLM

Run T

ime

Ecosystem

6

OTS Emulation

mCAD eCAD P&ID

Simulation

Modeling


System Interaction

7

Design Time

Interface

Run Time

Interface

PDM/PLM

mCAD

eCAD

P&ID

Simulation

OTS

Modeling


Agenda


Virtual Design




Collaborative Engineering Trends

Strong pressure for engineering efficiency and reduced project times.

In manufacturing, time to market and cost reduction pressures is

forcing users to reduce the whole lifecycle from concept to production.

There’s a need to integrate manufacturing design earlier in the

process that requires closing data and collaboration gaps.

For machine builders, there’s a pressure for more flexible, safe and

smart machines. This is requiring a much higher degree of electrical

and control in the machine design, thus requiring concurrent design of

mechanical, electrical and controls.

9


Data Exchange


System Framework

SUPERVISORY

NETWORK

CONTROL

11


Define the System

12

Architect


Collaborative Data ExchangeGetting Data into the System


IAB Export to Studio 5000 Architect™

Allows for the export of control systems created in Integrated Architecture® Builder to Architect and the automatic creation of the corresponding Logix Designer project files

Helps eliminate data entry redundancy

Reduces design time by matching the BOM with the actual project

Architect


Collaborative Data Exchange


EPLAN Bi-Directional Synchronization

Synchronizes data transfer of Hardware configuration and Point Tags (Alias Tags)

Allows for automated schematic updates in EPLAN

Improves start-up time helping ensure electrical drawings are perfectly matched to I/O assignments

Architect


Collaborative Data Exchange


Collaboration


Saving Merge…

Cancel


Agenda


Virtual Design




Market Drivers

Virtual Design is Focused on Rapid Design, Test, and Optimization

Cost effective way to validate

controller code, HMI screens, and

device settings

Troubleshooting system without

investing in physical hardware


Minimized damage to field

equipment

Increased productivity - shortened design

cycle and faster time to market

Avoid costly mechanical prototypes

Reduced migration risks by better

understanding system behaviors prior to

connecting to real machine

Automated design tool integration

Virtual Design Trends


Mechanical

Electrical


Programmer


Programmer

Virtual Designer


Levels of Virtual Design

Simple Mechanisms

• Pumps

• Knife

Machines / Lines

• Packaging Lines

• Production Cells

• Tank Farms

• Web Handling Lines

Complex Applications

• Wind Turbines

• Compressors

• Winders

Plants / Processes

• Logistics

• Bottleneck Analysis

• Resource Allocation

• Production Processes

Complexity


The Cost of Virtual Design

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 machine.

Cos

t

There’s a compromise between the level of

detail and the cost of virtual design

Level of FidelityBasic Realist

Level of SimulationParts System

HIL

SIL

Emulate

Risk


Simulation vs. Emulation

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

system/computer.

We emulate Controllers, IO 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

Simulation are necessary

Virtual Design & Engineering

Process Simulation

Equipment Simulation

Control System

Emulation


Emulated control system connected to models simulating plant or process

Verify system behavior of production code on host computer

Cost – effective method for evaluating complex critical software before deploying to real world

Software in the Loop (SiL)

Emulate 5000 Simulink


Develop and Validate Control SystemsSIL Using MATLAB Simulink


Hardware in the Loop (HiL)

A simulation system with the control hardware and I/O devices interacting with the

simulation running in a simulation environment.

The control algorithm runs in the controller hardware connected to simulated plant

A special card in the chassis runs the plant model plus I/O module simulation

Closest to the real application

Real controller indented for production


Simulink® and Stateflow• Model dynamic systems• Design control algorithms• Test control systems

using simulation

Studio 5000™ Logix Designer

Real-timecommunication via

EtherNet/IP™

Simulink Coder™• Generate ANSI C Code from plant

or process models• Deploy the code to Simulink Real-

Time running on a real-time computer

Simulink PLC Coder™• Generate IEC 61131 structured text

from control algorithms• Import structured text into Logix

Designer as an AOI or routine

Speedgoat Real-Time Target Machine• Utilize Intel CPU and Xilinx FPGA technology

Simulink Real-Time™• Run real-time simulations from Simulink

models microsecond granularity and concurrent execution support

CompactLogix industrial controller

Machine and Process Models

Supervisory and Closed-Loop Control Algorithms

Develop and Validate Control SystemsHIL Using Real Time Simulation


Develop and Validate Control SystemsRapid Design, Test, Optimization


FMI Based Co-Simulation

37

Functional Mockup (FMI) OPC


Functional Mock-up Interface

38

Tool independent standard to support both model exchange and

co-simulation of dynamic models.


Agenda


Virtual Design

Collaboration Engineering



Average Operator Age >50

7 Years to Operator Competency

5 Year Average Tenure

Process Simulators with Operator Training

Systems are the answer

Equipping Operators of the FutureIndustry Workforce in Transition


Pilot – over 100 variables

Operator – over 1000 variables!

Dynamic Simulation Can Help


High Fidelity Process SimulationTight Integration with Mynah Mimic


Feed 1

Feed 2

Condenser

Cooling water Fcw

Reflux Drum

Lc, Vc_out

Reflux L_R

Distillate product L_D

CW Out

V_DA_VD1

A_Vlv1

Reboiler

A_v

L_B + V_B

V_B

Buttom product L_B

Heating steam

HE condensate

Side withdraw 2

Side withdraw 1

Heavy liquid L_HvLiq

Vnt

V_D1

Studio 5000 Design Environment

Mimic Simulation Software

Introducing the Virtual Plant


Operator Experience

SY07 - Leverage Virtual Design to Build a Better System

Technology

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