Virtual Commissioning for Press Line Setup
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Solution Overview
Problem
The commissioning process of automated manufacturing systems, such as press lines, is time-consuming and prone to errors, leading to significant delays and lost production time, especially during the setup of new die sets or after major kinematics changes, where system errors are often detected late and are difficult to repair.
Innovation Solution
A system and method for virtual commissioning and setup of automated machinery, which involves loading a machine operating model, receiving machine-specific data, simulating machine operation to produce optimized motion data, and transmitting this data back to the controller for validation and optimization, allowing for a seamless transition from virtual to physical environments and reducing setup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional commissioning process is used for automated machinery, then the system can be implemented with conventional methods, but the commissioning process is time-consuming and prone to errors
Solution Approach 1:
The patent applies preliminary action by performing virtual commissioning and simulation of press line operations before actual physical assembly. The system loads machine operating models, receives machine-specific data from controllers, and simulates machine operations to detect errors in advance. This allows design and controller errors to be identified and corrected during the virtual commissioning phase, preventing them from manifesting during actual commissioning and production setup.
Solution Approach 2:
The patent creates a virtual copy of the press line system through machine operating models that replicate the behavior and characteristics of the actual physical press line. This virtual model includes simulated machine components, controllers, and operational parameters that mirror the real system. By working with this accurate copy in the virtual environment, the system enables error detection and optimization without risking the actual equipment or production time.
2Ease of manufacture
If virtual commissioning simulation is performed, then errors can be detected early, but additional simulation processing time is required
Solution Approach 1:
The simulation process performs setup and error detection activities in advance before actual physical assembly and commissioning. By loading machine operating models and simulating operations beforehand, the system identifies issues during the virtual phase when changes can be made without physical rework, thereby easing the actual manufacturing setup process.
Solution Approach 2:
The system implements feedback by transmitting optimized motion data from the simulation back to the automated machinery controller. The simulation analyzes machine-specific data, identifies optimization opportunities, and returns corrected motion profiles that improve actual machine operation. This closed-loop feedback ensures that lessons learned in simulation directly benefit physical commissioning and operation.
3Productivity
If optimized motion data is transmitted to controller, then operational efficiency is improved, but data transmission and processing time is added
Solution Approach 1:
The system establishes a feedback loop where optimized motion data generated from simulation is transmitted back to the automated machinery controller. This feedback mechanism allows the controller to operate with pre-optimized parameters that improve productivity and operational efficiency. The data transmission time is minimal compared to the overall time savings achieved by avoiding physical trial-and-error commissioning and reducing setup iterations.
Data Source
AI summary
A system, method, machine-readable medium for accurate simulation of automated machinery. A method includes loading a machine operating model. The method also includes receiving machine-specific data from an automated machinery controller. The method also includes simulating a machine operation using the machine-specific data and the machine operating model to produce optimized motion data. The method includes transmitting the optimized data to the automated machinery controller by the simulation data processing system.