Virtual Commissioning

Virtual Commissioning covers the use of simulation to plan, design, test, and install production systems

MBSE and Virtual Commissioning: Do the Two Intersect?

The engineers who design production systems are not strangers to complexity. This raises the question: Can systems engineering be applied to the development of production systems? Let’s explore how, by discussing systems engineering and model-based system engineering.

The Digital Thread: Is It Applicable to Virtual Commissioning?

Digitization is complicated. In this VirtualCommissioning.com post, we’ll explain and examine the emerging Digital Thread concept, investigate where the Digital Thread intersects virtual commissioning, the impact this concept has on organizations, and the opportunities a Digital Thread can bring to businesses.

WHAT IS A DIGITAL TWIN OF A PRODUCTION SYSTEM AND WHY WOULD YOU WANT TO USE IT?

A digital twin of a production system feeds production line sensor data into a simulation of the production line. You can then measure virtual sensors and capture virtual sensor data off of the simulation. When you combine that with the physical sensor data, you have a richer view into what is actually happening in the production system overall. In this post, Chad Jackson discusses the value of running virtual and physical sensors together.

Digital Twins of production systems. 1D? 3D? What is the best fit?

Commissioning production systems is no easy task. The effort is complex. The schedule is short. Everyone wants to minimize downtime in facilities and plants. Getting a head start on commissioning through virtual methods instead of waiting for physical hardware is a step in the right direction. However, when it comes to the tactics of virtual commissioning, there are multiple options. Some organizations use 1D simulation process models. Others leverage detailed 3D designs with animations. Yet others use combinations of these two approaches. In this post, we’ll take a look at each, identifying the advantages and disadvantages of these different methods.

WHAT IS FMI? HOW IS IT RELATED TO VIRTUAL COMMISSIONING?

To enable virtual commissioning, models are created that emulate the behavior of individual components in the system. Such simulation models have two sides, representing the logical controllers and the physical components of that system. This post will address some of the shortcomings associated with the models used to enable virtual commissioning and introduce potential solutions.

THE ROLE OF A COMPONENT LIBRARY IN VIRTUAL COMMISSIONING

To successfully develop simulations for virtual commissioning, two core technology enablers are required. The first is the software application that builds and runs the simulation. The second is a library of the virtual components required to build the models. This post examines the importance of the component library.

WHAT IS THE VALUE OF VIRTUAL COMMISSIONING?

Instead of doing physical commissioning exclusively, where you’re iterating and debugging with many delays, you can use virtually commission along the way to speed up production. As a matter of fact, you can even integrate these 1D simulations with the hardware, the PLC’s, and validate that everything works correctly before the physical commissioning starts.

WHAT IS A DIGITAL TWIN FOR VIRTUAL COMMISSIONING?

There’s no doubt about it: today’s production systems are becoming incredibly complex. Machinery, cells, lines, and entire facilities leveraged new and innovative sensors, electronics and programmable logic controllers (PLC) to do some pretty amazing things. The future of the smart factory is now.

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