Simulation-based engineering

Flexible and cost-optimized engineering processes

Beyond the one-time use of digital twins for virtual commissioning, plant and machine builders as well as production companies in various industries increasingly rely on so-called "simulation-based engineering".

This consistent, profitable use of ISG-virtuos as a "dynamic specification" leads to significantly higher software quality with the same manpower in a shorter time, and the automation of machines and plants starts at a very early stage. The connection of systems to higher-level control systems can also be significantly shortened by preceding virtual connection. Risks in project management and during commissioning at the customer's site are significantly reduced, especially through virtual acceptance.

In the case of manufacturers who use different control systems, the verified functionality of the control system mainly used can be transferred to controls from other manufacturers and fully tested, even if the real system is not available. Mechatronic solutions form the basis for this: The respective components are modeled, verified and accepted in mechanics (including 3D representation) and in behavior (electrics, pneumatics, hydraulics, etc.) and then stored in module libraries of the simulation system for reuse.

Higher software quality thanks to the continuous use of virtual plants
Higher software quality thanks to the continuous use of virtual plants
Stages of simulation-based engineering
Stages of simulation-based engineering

Phases of simulation-based engineering

Design/development, product/performance optimization, commissioning

Using original engineering data, the requirements of all participants are developed, checked and optimized on the virtual system from the very beginning. Here, the real controller connected via the real fieldbus is used.

Already existing CAD data and electrical configurations can be imported directly into ISG-virtuos. During virtual commissioning (VIBN), the virtual system is put into operation and accepted in the form of a virtual factory acceptance test (FAT).

Finally, the accepted control functionality is transferred 1:1 to the real system. Due to the software design specialized in real-time control, this transfer can be carried out without any further adjustments. The real system is then ready for operation without any rework.

During operation of the real system, the virtual system continues to be used profitably as a digital twin:

  •     New machining sequences and production processes are checked and optimized without endangering the real system and interfering with ongoing production, including collision detection.
  •     Messages from customers regarding performance or malfunction situations are checked on the simulation system. The real system is corrected or optimized via remote access or by service personnel on site.
  •     Modernization and retrofitting of existing systems are carried out on the basis of the simulation model including the real control technology. The conversion or downtime of the real system is significantly reduced.
  •     Training of operating and maintenance personnel is carried out on the real control system, which is connected to the digital twin. This means that operating errors no longer represent a risk. Instead, malfunction situations are deliberately provoked in order to train the elimination of such malfunctions in practice.