Five innovations for engineering

Automation Five innovations for engineering

2024-10-14 Source: Bosch Rexroth, Festo, ISG Steuerungstechnik, Machineering, Perspectix | Translated by AI 5 min Reading Time

Related Vendors

machineering GmbH & Co. KG

Perspectix AG

ISG Industrielle Steuerungstechnik GmbH

Bosch Rexroth AG

Festo SE & Co. KG

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We introduce five new solutions for engineering in automation. It involves digital twins, simulation, and new apps.

Here, new and improved solutions for simulation and design are in focus. For example, Festo is working on a seamless and break-free communication technology and uses the asset administration shell as a central information object.(Image: Festo) — Here, new and improved solutions for simulation and design are in focus. For example, Festo is working on a seamless and break-free communication technology and uses the asset administration shell as a central information object.
(Image: Festo)

Automation components: Digital twins accelerate machine development

Faster time-to-market, more efficient engineering, increased functionality, and higher quality—these are the advantages of a digital twin for machine and plant manufacturers. Festo is working intensively on equipping its components with a digital twin in the form of administration shells. Until now, a multitude of data existed for each automation component in various formats such as CAD, PDF, or even paper manuals. Data management was cumbersome and difficult to access throughout the entire lifecycle. This lack of digital continuity also made full networking of all objects more difficult. Therefore, Festo is working on a seamless and integrated communication technology, using the administration shell as the central information object.

Tests and adjustments in the virtual model

In the virtual model, the developer can test whether they can, for example, move the carriage and view the process data from the displacement measurement system or the signal of the limit position sensors. If they want to create the control sequences for the machine, the developer has access to the capabilities of components such as extending, rotating, or gripping, with which they can assemble the sequence. Additional value-added services can also be implemented based on digital twins.

Before components in operation reach the end of their service life, condition monitoring will alert. The digital twin of the machine could then automatically order replacement parts. Also, future changes to the machine can be developed and tested in advance on the virtual model using digital twins.

Festo at SPS 2024: Hall 9, Booth 305

Digital Marketplace: New apps facilitate automation tasks

The digital marketplace, which now includes over 80 apps across 16 main categories, is continuously growing.
(Image:Bosch Rexroth)

All necessary applications and services for automation in one place—this "One-Stop-Shop" principle is implemented by Bosch Rexroth with its ctrlX OS Store. The digital marketplace is continuously growing. The wide range includes everything from engineering apps to simplify development projects, motion solutions, to security applications.

New apps include:

The solution Model Connect offers an alternative to traditional PLC programming. It connects ctrlX OS devices with powerful model-based software development systems, which improve the efficiency and quality of software. The first version supports Matlab and Simulink. This allows complex systems such as machines or specific process or control technologies to be developed, validated, and simulated more easily through models.
The ctrlX Motion app now features an API extension. This allows users to enhance the app with their own motion expertise, supporting up to 128 drives.
The ctrlX Works Engineering is now modularly structured and uploads required engineering tools as needed.

Bosch Rexroth at SPS 2024: Hall 7, Booth 450

Simulation: Making projects more efficient and flexible

ISG Control Technology has released version 3.6 of its simulation software ISG-virtuos, emphasizing that user-friendliness was a priority in the development. Key functions have been consolidated into clear functional areas and, thanks to the new favorites tab in the merged Model Library and the new pie menu in the 3D view, users can save frequently used components.

The software also offers many innovations in the area of simulation. With new components such as the Slider-Crank mechanism or the Lightgrid component for light barriers, simulations become even more detailed. With the Dynamic Port Manipulation feature, users can dynamically manipulate model block ports during the simulation, for example by adding or multiplying values—more customization freedom, fewer simulation restarts.
Version 3.6 also brings new features and improvements in control connection and co-simulation. In the area of co-simulation, complex simulations can now be conducted on Windows-based systems and B&R controllers. In addition to the now available "Threaded Mode with Sync" for the PLCSIM Connector, there have been extensive enhancements to the Connector Manager. Connectors such as OPC/UA, Acontis EC Simulator, ADS Connector, and TC-Variable Connector have been added, and the integration of B&R systems via Powerlink and TCP/IP or B&R PVI Connector is now possible.
The manufacturer highlights the expanded JavaScript interface as another key feature. With it, models can not only be created directly via code, but complex configurations and settings can also be automated. New opportunities also arise in the field of C# programming. The new interface for simple logic construction is ideal for rapid prototyping of new fieldbus devices.

ISG Steuerungstechnik at SPS 2024: Hall 6, Booth 338

Simulation: Improvements in performance and data security

According to the manufacturer Machineering, the simulation solution I-Physics version 3.4 introduces important updates that enhance performance and ensure the protection of know-how and data security during cross-company collaborations.

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Key Innovations:

Multiple Physics Engines: Users can now deploy multiple, individually parameterized physics engines simultaneously within a single model.
Increased data security: Introduction of password-protected assemblies and a new encrypted file format (.iphc).
Tools for modeling and script editing: The new web-based ModelScript Editor and the LLVM-based ModelScript Compiler (both in beta version) enable more efficient creation and editing of models.
Enhanced features for more realistic simulations: Introduction of a kinematic bending kernel and an FMU interface for drive simulations.
Innovative operation and visualization tools: Improved measurement functions and visual effects such as lens distortion and depth of field.

Machineering at SPS 2024: Hall 6, Booth 310

Engineering: Digital plant twins from a modular system

Manufacturers of complex machinery increasingly rely on digital twins for the planning of customer-specific variations: planning errors are avoided and coordination with customers is improved through 3D models and comprehensive information. They are also developing new business models for after-sales service and spare parts. With the P'X Industry Solution from Perspectix, digital twins can be created from a modular system. In the context of 3D building data, collision-free facilities are developed.

With P'X Industry Solution, digital twins can be created from a modular system. Plant constructors avoid planning errors and thus improve coordination with clients through 3D models and comprehensive information.
(Image:Gorodenkoff - stock.adobe.com - Perspectix)

Digital Twins from Reduced CAD Models

The configurable plant components, with over 100 parameters and constraints, are placed using "drag and drop" in the IFC format of Building Information Modeling (BIM). Functional units can be associatively linked and checked for changes. These digital twins are created using the P'X Industry Solution from product catalogs with reduced CAD models. Product logic and parametrics are mapped in rule sets that ensure quick and error-free product variants. The P'X Industry Solution integrates with existing ERP, PDM, and CAD systems. All documents such as bills of materials, 3D images, or assembly instructions can be customized and automatically generated.