ISG - virtuos

Digital twins in real-time control

Necessity of HiL simulation

Shorter production times, greater pressure on costs and deadlines, increasing variant diversity, decreasing lot sizes and the resulting changeover times etc. Companies in many industrial sectors are facing the challenge of keeping their machines, plants and robots efficient despite the increasing number of ever more stringent requirements. For this reason, many manufacturers and operators are opting for system digitisation and networking - totally in line with Industry 4.0.

Particularly fast processes in the fields of machine/plant engineering and robot technology place high demands on the simulation of automation systems where the simulation is intended to replicate the response of a real machine without any restrictions. Given their lack of real-time capability, this is the point where most simulation systems reach the end of their limits.

Module-based HiL (hardware-in-the-loop) simulation with ISG-virtuos

The specialised software design of ISG-virtuos is intended for real-time applications and permits the hardware-in-the-loop simulation (HILS) of automation systems in hard real time ("control real time" (<1ms)). The connection between control and simulation is established over common fieldbus systems and is therefore independent of the control manufacturer.

Virtual machines, plants and robots are set up with virtual components that are identical to the real components with regard to the interfaces, parameters and operation modes. These virtual systems (so-called “digital twins“) simulate realistic test and commissioning situations, including all control functions in sequence (PLC) and motion control (MC, RC, CNC). System tests can also be automated. Functions developed and tested in this way are then easily transferred to real systems.

The advantages of the components-based software are obvious:

Please find a summary of the most important features on the website.

Since 2005, our digital twins have been successfully installed and used by leading plant and machine producers as well as production companies in a number of different fields – for virtual commissioning or beyond that as an 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 look forward to receiving your request - do not hesitate to contact us.

Digital twins in real-time control: Simulation environment with ISG-virtuos (here: Beckhoff CX2040 via EtherCAT)

ISG-virtuos: Engineering and virtual commissioning in hard real time

Carefully matched software and hardware components

Integration interface for many offline programming systems (KUKA OfficeLite, FANUC Roboguide, ABB RobotStudio, etc.)

Individual module libraries for reusable models

Integrated engineering tools

Direct adoption of engineering data from existing systems

Module library for removal simulation

Physics-based material flow "MFphys"

3D visualisation of simulation results

Compatible controllers and fieldbuses

Directly transferable CAD data formats (readers)

System requirements for hardware-in-the-loop applications

Intel Core i7 3.0 GHz processor and higher * 16 GB RAM * Graphic card GTX970 and higher * 256 GB SSD drive * HDD 1TB * Power supply 750W and higher * Real-time OS TwinCAT V3.1 C++ * PCIe / PCI slots. Operating systems supported: Windows 7, 64-bit * Windows 10 * Linux. Note: System performance and speed can be increased by using processor, storage capacity and available disk space that exceed the minimum requirements.

In order to guarantee the site-independent, cost-effective and fast application of the test system, ISG-virtuos runs on commercial PC technology. Operation is possible without control hardware for offline simulation. ISG-virtuos can be installed on an unlimited number of PCs. The purchased license is activated via dongle.

Recommendation: We can also supply simulation PCs tailored to customer requirements.

ISG-virtuos is introduced by specific implementation trainings in which actual customer projects are implemented. Experience shows that this procedure noticeably reduces the cost and effort of introducing simulation technology and ROI is much faster.

Further information: