Necessity for HiL simulation
Shorter production times, tightened pressure on costs and deadlines, increasing variant diversity, decreasing lot sizes and thereof resulting changeover times... Companies in many industrial sectors are facing the challenge of keeping their machines, plants and robots efficient despite various and ever-growing requirements.
Particularly fast processes in the fields of machine / plant production and robot technology pose high demands on the simulation of automation systems if the simulation is meant to replicate the behavior of a real machine without any restrictions. Given their missing realtime capability, this is the point where most simulation systems are reaching their limits.
Module-based HiL simulation in control realtime with ISG-virtuos
ISG-virtuos' software design is specialized on realtime applications and enables the hardware in the loop simulation (HILS) of automation systems in hard realtime ("control realtime" (<1ms)). The connection between control and simulation is established via common fieldbus systems and thus independent of the control manufacturer.
The virtual machines, plants and robots are set up with virtual components that are identical to the real components regarding the interfaces, parameters and operation modes.
By means of these virtual systems (the so-called „digital twins“), realistic test and commissioning situations – including all control functions in sequence and motion control (MC, RC, CNC) – are simulated. These system tests can also be effected automatically. The thus developed and tested functions are then easily transferred onto the real systems.
The advantages of the components-based software are obvious:
- The virtual components are created once and, stored in module libraries, are always ready for re-use in new systems.
- When existing systems need to be changed, it is not necessary to redesign the complete system. Instead, only the changed component is replaced and connected to the existing system.
Please find a summary on the most important features in the latest product overview.
Since 2005, our digital twins are successfully applied by leading plant and machine producers as well as production companies in different fields – for virtual commissioning or beyond that as important element of simulation-based engineering.
Given its open software architecture ISG-virtuos supports the automation and engineering of machines, plants and robots irrespective of the industrial sector. We are looking forward to receiving your request - do not hesitate to contact us.
System requirements for hardware in the loop applications
Processor Intel Core i7 3.0 GHz and more * 16 GB RAM * graphics board GTX970 and more * drive SSD 256 GB * HDD 1TB * power supply 750W and more * realtime OS TwinCAT V3.1 C++ * slots PCIe / PCI. Supported operating system: Windows 7, 64 Bit. Note: The systems performance and speed can be increased by applying processor, storage capacity and available disk space that exceed the minimum requirements.
In order to guarantee a location-independent, cost-effective and fast application of the test system, ISG-virtuos runs on commercial PC technology. The operation without control hardware for offline simulation is possible. ISG-virtuos can be installed on an unlimited number of PCs. The activation of the obtained license is effected via dongle. Simulation PCs that match our clients' requirements can be supplied.
ISG-virtuos is introduced via specific implementation trainings in which specific clients’ projects are implemented. Experience shows that in doing so, introductory efforts are remarkably reduced and ROI is quickly reached.