Schmersal presents 4D model of safety components at SPS 2024.

Safety Digital twin for machine safety

2024-11-11 Source: Press release. | Translated by AI 2 min Reading Time

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Schmersal presents a 4D model of its safety components for the first time at SPS 2024 in Nuremberg (Germany): a digital twin of the safety guard AZM40 and the door handle system DHS.

The Schmersal Safety 4D model simulates all the properties and functions of the physical safety switching devices.(Image: K.A. Schmersal GmbH & Co. KG) — The Schmersal Safety 4D model simulates all the properties and functions of the physical safety switching devices.
(Image: K.A. Schmersal GmbH & Co. KG)

In addition to the three-dimensional representation (3D), the virtual image simulates all the properties and functions of the physical devices as a fourth dimension (4D). For example, if a safety door is unlocked using the real button on the door handle, the LEDs light up on the digital twin just like on the physical counterpart. According to its own statements, Schmersal is one of the first companies to develop a digital twin for safety components.

Virtual commissioning of the machine possible

The Schmersal Safety 4D model not only simulates individual components but also entire process or control sequences through the virtual mapping of signal flows. The advantage: with the help of the 4D model, early error detection and optimization, as well as the virtual commissioning of the machine, can be carried out even before the real machine is mechanically assembled. This saves costs and unnecessary development loops. In the future, it should also be possible to monitor the components as a prerequisite for predictive maintenance.

“We plan to offer the Schmersal Safety 4D model to our customers as a service in the future, for example, via our homepage or through the online store for 4D models 'TwinStore'—a platform where component and system suppliers provide their digital twins,” says Volker Heinzer, Strategic Product Manager for Programmable Electronic Systems and Industry 4.0 / IIoT at the Schmersal Group. Digital "model catalogs" with the 4D models of Schmersal products are to be gradually built up for this purpose.

Lossless real-time physics simulation

For the Safety 4D model, Schmersal uses the simulation software ISG-virtuos from ISG Industrielle Steuerungstechnik GmbH. The computationally intensive simulation model is calculated on the ISG-Realtime Target. With this powerful ultra-compact industrial PC, it is possible to perform a lossless real-time physics simulation. From the control perspective, it represents the entire machine or system, is mobile due to its compact design, and can also be installed in the control cabinet.

Schmersal showcases its products and solutions from November 12 to 14, 2024, at SPS in Nuremberg in Hall 9, Stand 460.

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