Plant Simulation as a Service

Higher quality and reduced costs for

your products and processes

Your benefits at a glance

Shortening of commissioning times Minimisation of costs

Avoidance of collisions without interference with real
operation
Reduction and avoidance of production standstills
Improved software quality
Possibilities for operator training
Optimisation of the production processes/logistics
Increased productivity
 Plant Simulation

Simulation services

HIL simulation

BoHleneck analysis
Plant op+misa+on
Throughput calcula+on
Material ow calcula+on
Increase of produc+vity
Material flow simulation

Virtual reality

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 So9ware op+misa+on
Operator training Time op+misa+on
Cost reduc+on HIL test enviroment

Hydraulics simulation

Hydraulics calcula+on
Process analysis
Energy balance
Fault analysis
Control

Spare parts Energy flow simulation

Customer presenta+on
Stereoscopy 3D visualisa+on
Collision analysis

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 Plant Simulation

HIL simulation
Virtual test environment for effective
software development and commissioning

Prototypes & new plants

A smooth market launch of newly developed

systems is now very simple thanks to modern
virtual test environments. Parallel to the pro-
duction of the first machine parts, the machine
software undergoes exhaustive analysis and
optimisation in the test field of the SMS group.
The CAD data are thereby projected onto a
screen and the movements and material flow
can be observed in real-time.

The real controller with the programmed automation software is linked to the
simulation computer via the dedicated field bus interface following the Hardware-
In-The-Loop (HIL) approach. The outputs from the PLC are read out and input
into the simulation model. Depending on the signals, the model performs virtual
actions, such as e.g. the switching of a solenoid valve, that can lead to a cylinder
being extended. The movement is displayed in the 3D model and resulting signal
changes, such as the tripping of a limit switch (here: cylinder is extended), are
written back to the controller by the model (PLC inputs). The programmer is
therefore able to operate and test the machine in real-time even before com-
missioning. Thanks to this innovative virtual commissioning approach, expensive
collisions can be recognised and prevented in good time, and numerous problems
and time-consuming work on the customers site can be avoided. Programming
errors can thus be detected and remedied much faster and more easily.

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Highly complex production lines

The virtual test environment allows even highly complex systems to be tested in
combination. The communication between host computer, transport systems and
machining centres and the respective programs can be analysed and developed
further using the HIL approach. Benefits are gained when individual systems are
already integrated into the production process and a production standstill has to
be avoided.

PLC software optimisation

The final machine movements generally take place during commissioning in the
customers works. The goal of the programmer here is to avoid collisions and to
fulfil the required function. Due to a lack of time and a shortage of the necessary
tools, machine movements are seldom optimised. A simulation opens up a wide
range of possibilities for optimisation here, particularly for the PLC software.
Machine movements can then be designed so that extreme vibrations from the
system are reduced. This protects the material and the expected service life is
prolonged, and even an increase in material throughput can be achieved in this
way, so that simple modifications to the software alone allow an increase in
productivity.

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 Plant Simulation

Virtual Commissioning

Virtual commissioning of a tube welding line

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Virtual commissioning offers a wide range of benefits that become particularly
apparent in project management and the integrated time management. Internati-
onal teams often work together on a project, and the project manager is ultima-
tely responsible for ensuring that commissioning is smooth and on schedule. In
order to avoid the programmer turning up in the customers works with software
that is not yet finished, testing in advance as part of a virtual commissioning is
absolutely essential. This approach is indispensable today, as the continuous
increase in software complexity means that you can no longer see from the
outside whether or not a program is complete and fault-free.

Apart from the objectively measurable benefits, virtual commissioning naturally

also offers a multitude of soft benefits. These include, for example, no risk of
crashes, tests of new functions and operator training without interference with
production and steeper ramp-up curves for the production line during commissio-
ning, as setting parameters can be found faster and more easily.

Engineerimg drawing of plant shown in the left picture

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 Plant Simulation

Expansion and Optimisation of

Existing Plants
Virtual planning and implementation of your ideas

Not only new developments present a company with major challenges; the re- Incorporation of original design data
vamping, expansion or optimisation of existing machines and plants is becoming
The integration of the 3D CAD data allows the
more and more commonplace. Plant simulation is a very powerful tool especially
whole production process to be analysed very
here. No-one wants the production processes standing still for longer than ab-
precisely. As a result, design errors or collision
solutely necessary, or wants to worry about the machine no longer being pro-
risks can be recognised and eliminated in good
ductive after the revamping. A high-quality plant simulation allows these risks to
time. Technical processes and safety functions
be minimised in advance.
can be observed in quasi-reality and improved, if
necessary.

Validation of the engineering data

The technical engineering data, such as electrical

circuit diagram, hydraulic circuit diagram,
description of functions, etc. form the basis for
the preparation of the simulation so that these
are already examined very closely during the
creation of the model. Incorrect relationships
and errors within the data are immediately re-
cognised and can be remedied in good time, thus
saving further costs.

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Virtual HMI

The HIL test environment offers the possibility of linking real control desks to the
simulation system. Functions and links between the control links can therefore be
tested in advance. For organisational reasons, however, it is often not possible to
make the control desks available for the virtual tests.

The solution to this problem is virtual HMI. Thanks to the virtual simulation of
the control desks it is possible to adopt the design and all the functions of the
control desks. This ensures that the machine can be fully tested and realistic
control of the machine is assured.

Operator training and debugging using a digital twin

Particularly in the virtual world, no-one has to be concerned that the machine
could be damaged due to an operator error. This advantage is frequently used by
customers to train their staff in advance before they are allowed to operate the
real machine. The simulation enables special error scenarios to be called up at
the press of a button in order to study important operating routines without risk.
Training directly at the virtual machine is well received by the operators, as they
can safely control the machine and test out all the functions. The operator quickly
gets to know his machine using the virtual model and can thus be gradually pre-
pared for his new duties.
The benefits at a glance
It is also possible to transfer special situations from the real production machine
to the digital twin in order to virtually simulate and analyse fault scenarios that
Remedying of faults in the engineering
data in good time
may be attributable to an error in the programming. The situation can therefore
be analysed without stress and the pressure of time while production continues Error detection and remedying in the PLC
to run in parallel. software

Testing and correction, if necessary, of the

safety functions and technical processes

Detection of design errors

Avoidance of real collisions

Reduction in commissioning time

Optimisation of a wire rod mill Operator training

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 Plant Simulation

Process simulation
Physics models in Matlab SIMULINK

In addition to HIL real-time simulation,

process simulation offers an enormous
array of new perspectives for new
developments, but also for problems oc-
curring in existing machines and plants.
Process simulations are therefore regu-
larly used in the SMS group for the design
of technological processes. MATLAB
Simulink allows the engineers to calcula-
te complex multi-dimensional processes.
Particularly today, when energy-efficient
machines and plants are becoming more
and more important for our customers
in order for them to remain competitive,
process simulations help to simulate
and illustrate the dynamics of a machine
part, the resulting control behaviour, the
forces involved or even the energy flows
in a model. As a result, the whole beha-
viour of the machine, and in particular
the interactions, can be investigated and
optimised.

Multi-dimensional physics simulation

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Linking of HIL real-time simulation and physics simulation

The Simulation department of the SMS group has gone one step
further than the conventional applications of physics models. A
method has been developed by means of which physics models can be
integrated into a real-time simulation. This approach is unique and
offers a large number of benefits. The programmer is thus able not
only to initiate and observe individual movements of the machine,
but can also draw on the calculation results for physical parameters
calculated parallel to the real-time simulation. The programmer can
then see, for example, the material deformation resulting from posi-
tions and speeds and can set his control parameters using the virtual
model.

Realistic machine behaviour using the game and physics engine

A game engine (with integrated physics engine) is used to realistically

image the material flow and to give the user of the simulation the
feeling of standing in front of the real machine. This engine cyclically
calculates simple physical effects, such as gravity and friction. This
is a great benefit with very complex processes, such as a production
facility the size of a football field. Frequently even minor phenomena
are detected here, such as a blank rolling away or the collision between
materials. The coupling of the game engine to the HIL simulation is an
in-house development of the SMS group and not available in this form
on the market.

Coupling of physics engine and real-time simulation

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 Plant Simulation

Virtual reality
Interactive realistic perception

Interactive 3D model for spare part identification and ordering

The spare parts service of the future

Which customer is not worried about a production standstill? If a component

breaks or fails, fast help is crucial. Every minute of standstill results in high costs.
The interactive and virtual spare parts service concept of the SMS group makes
this fast help possible. The customer receives a virtual tool with which he can
view his machine in a 3D model and have spare parts displayed individually.
As a result, he is both well informed and can order spare parts directly from the
manufacturer with just a few clicks, i.e. with minimum effort and loss of time.

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Convincing customers of a product is always a great
challenge particularly when the product is still in the
development phase. Presenting the customer with
something tangible here generally involves consider-
able expense and requires special techniques. More
and more companies are now following new paths and
taking advantage of the very impressive and varied
possibilities offered by virtual reality. Here you enter
an interactive virtual environment and gain a realistic
impression of a product or a whole plant. This enables
the customer to get a very quick but thorough over-
view so that he is able to discuss his wishes with the
developers.
Further benefits are the savings in cost and time
achieved through the substitution of expensive and
time-consuming production of prototypes or samples.
The optimum communication with the customer from
the outset helps to avoid errors in interpretation,
and hence costs and delays in the later delivery and
commissioning. Many companies also make use of this
technique at international trade fairs to strengthen
their competitiveness.
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 Plant Simulation

Material flow simulation

Planning, analysis, optimisation

Material flow simulation is an analysis tool for examining logistics processes in Material flow simulation of a wheel rolling line

a plant. Fields of application are performance measurement of a plant, but also

the generation of optimisation findings. Individual events are thereby defined
and then linked as in a network. Failure probabilities and tooling times can also
be taken into consideration in the simulation. The simulation time can be freely
selected so that an annual production can be calculated within a few minutes.
Reports then allow pie charts to be generated for individual machine parts show-
ing the loading as a percentage, making material flow simulation an optimum tool
for analysing and optimising production lines. The simulation also serves as a
successful basis for discussions, during which a suitable solution can be quickly
found. According to VDI 3633, the cost/benefit ratio of a material flow simulation
is 1:6. The costs are slightly higher during the planning phase, but are more than
recouped later in the operational phase.

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Boost productivity

Many machine and plant owners are faced with the great challenge of operating
their production facilities with the highest possible productivity. Just-in-time pro-
duction, in particular, is difficult to manage. When quantities vary widely and differ-
ent product types are produced in parallel on one line, plant operation becomes a
real challenge. Thanks to its many years of experience in material flow simulation
for industrial-scale plants, the Simulation department of the SMS group has found
an effective way of precisely describing a plant mathematically in order to analyse
the productivity.

The findings are then assessed together with the customer in order to identify the
most appropriate optimisation steps for him in the plant.

SRP-R 10000 DRAW

processing idle waiting for transporter processing idle blocked
28.33% waiting for transporter
43.32%

Waiting for
discharge Machining
1 3
PortalRobot 1 PortalRobot 2
travel empty travel loaded travel empty travel loaded
offset travel empty offset travel loaded offset travel empty offset travel loaded
idle idle
36.49% 42.54%
Waiting for
infeed

2 4

4 2

5 1

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 SE-354E Published on 06.10.2016 Circulation 500 Printed in Germany KD

SMS group GmbH

Ohlerkirchweg 66
41069 Mnchengladbach, Germany
Phone: +49 2161 350-1362
Fax: +49 2161 350-1857
E-mail: mark.haverkamp@sms-group.com
Internet: www.sms-group.com

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these
characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not
have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.