Virtual Plant Development Learning for the Industry of Tomorrow With Digital Twins

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Wuxi InfiMotion Technology Co., Ltd.

More and more extensive knowledge is required for system creation and programming and rapid further developments make conventional training difficult. A new learning method with virtual content, in which digital system twins can be used to set up and program self-made systems, allows for flexible, state-of-the-art learning.

As technology advances, learning and training methods must also change in order to keep pace with change. Here, too, digitalization has found its way in and uses the advantages of virtualization and digital twins for the training of PLC programmers. The PC-Lab 3D Studio software from MHJ—Software simulates typical mechatronic learning systems that are always state of the art. To further increase the practical relevance, the developers have created special interfaces and plug-ins with which the open source 3D software Blender can be seamlessly integrated into the workflow with PLC-Lab. Instead of using individual, pre-configured systems as before, individual, self-designed systems or system parts can now be used. The software now offers learning opportunities from budding designers to create models to trainees in the fields of mechatronics, electrical engineering or automation who take over the programming of the individual work processes.

Digital Twin With Real Advantages

Mapping different system scenarios in a virtual environment for training purposes has a whole range of advantages. Firstly, you can react flexibly and quickly to new trends, and secondly, expanding the digital twin costs nothing compared to real training systems and is also completely safe. Lecturers in the field of control technology can develop mechatronic models tailored to the curriculum, mechanical engineers can commission their systems or machines via virtual commissioning by linking them to a control system and thus check the functionality of the control program.

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In real training systems, processes such as drilling and milling are usually only simulated for cost and safety reasons, as vapors, chips, etc. can be produced here. In the digital twin, on the other hand, you can actually "drill and deburr" virtually and completely simulate errors in system design or programming, even for deep holes. In this way, it may be possible to detect errors that remain undetected when drilling is only simulated, such as premature stops, lack of cooling or if chips are not removed correctly.

Safe Learning

Trainees can learn a lot from this without any danger if a drill breaks or accumulating chips block the mechanics. Other typical scenarios that are illustrated include the transportation, processing, sorting and recognition of different workpieces. However, tasks such as quality checks, complete or simplified production processes, storage, fill level control, pick & place tasks and even precise positioning via drives can also be implemented virtually. This saves enormous costs compared to real training systems and also saves a lot of assembly time, which can be better used for learning content.

In order to further diversify such possibilities and also create special solutions for different industries in addition to the standard tasks, the training platform for collaboration with Blender has been expanded. This includes a fast import mechanism, an asset library with industrial components and a plugin that allows behavioral logic to be added to 3D objects. This means that individual plants can now also be created and new objects can be designed or imported.

Build Learning Program According to Requirements

PC-Lab 3D Studio uses Blender, a widely used and established 3D software that has a large user community and is also free of charge. The digital twin created with this software is then imported into PC-Lab 3D Studio and is ready for realistic system programming and a realistic 3D simulation. The system views can be freely selected in the room so that the "system operator" always has a clear view of all work processes.

To make it easier to get started, Blender already provides an object library with standard objects, such as actuators (sliding cylinders), sensors (optical, magnetic, capacitive) or conveyor belts, chutes, roller conveyors, etc. A large number of different system configurations can be quickly put together from these, for example by simply joining conveyor belts together using drag-and-drop. For new tasks or as an exercise for designers and advanced users, any number of individual objects can also be designed. This means that even very special systems can be created for industry-specific, practical training.

Educational institutions can use a digital twin as an interdisciplinary, joint project in which different specialist disciplines work together. Design engineers create the design drawings and cooperate with electrical engineers, mechatronics engineers and IT specialists to realize the digital twin.

Step By Step to the Digital Twin

The simulation environment is designed to make it easy to get started. The process can be divided into just six steps:

• First, a 3D model is created with Blender,
• then the objects are prepared; if they later have dynamic functions, they are marked with specific key words.
• The objects are then exported as a 3D model.
• The file is imported into PLC-Lab 3D Studio
• and then assigned and configured the skills to the objects.
• This is followed by virtual commissioning: The 3D model is switched to RUN mode and connected to a PLC or soft PLC.

Steps one to three are implemented in Blender, steps four to six with PLC-Lab 3D Studio. Errors are now often discovered during the simulation. Mechanical problems in the construction of the system, such as poorly positioned package deflectors that lead to a jam or protruding limiting plates or incorrectly set sensors or wrong actuators, are then usually easy to rectify in Blender. The project then has to be imported again and a new, improved system is available.

Get to the Bottom of Problems Quickly

Programming errors then need to be rectified, such as pusher movements that are too slow or too short in order to push parcels from the conveyor belt to the correct department or inadequate adjustment of the conveyor belt speed in order to separate goods. Such problems can also be quickly identified in the simulation. Once the system is running, the processes can be further optimized by fine-tuning the process-relevant parameters. If the standard objects from the library are not sufficient for a smooth process, you can also add your own objects at this point.

The procedure largely corresponds to that used for complex systems in industry. CAD data can also be imported as the basis for the Blender model. The flexibility of PLC-Lab also applies to the wide range of common industrial software products with which the system is compatible, including S7-PLCSIM from the TIA Portal or real S7-300/1200(G2) /1500 controllers from Siemens, Codesys V3-based controllers linkable via OPC/UA and many more. PLC-Lab 3D Studio in combination with the 3D software Blender is therefore ideal for learning with different control programs, as they are also common in industrial practice.

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