ISG-Virtuos Sindex (2014)

Implementation of a CNC machine with
Beckhoff-CNC
- Hardware-in-the-Loop simulation in
realtime (1ms) with ISG-virtuos -
ISG-virtuos SINDEX 2014
ISG 2014
SINDEX - 2014
ISG
Expertise in
control and simulation
VIBN
Virtual implementation
profitable benefit
ISG-virtuos
Hardware-in-the-Loop
in control realtime (1ms)
ISG-virtuos
& TwinCAT 3
with Beckhoff CNC / PLC
ISG 2014
ISG Industrielle Steuerungstechnik GmbH

Business areas
ISG
Industrielle Steuerungstechnik GmbH

Dr.-Ing. Dieter Scheifele
Business area
ISG-kernel (since 1987)
Control software
CNC, RC, Motion Control
Customers
control-, machine- and plant manufacturers
Business area
ISG-virtuos (since 2005)
Simulation software
virtual implementation (VIBN),

Hardware-in-the-Loop in realtime (1ms),
simulation-based engineering
Customers
machine and plant manufacturers,

engineering offices (integrators),
plant operators
ISG 2014
ISG Industrielle Steuerungstechnik GmbH

ISG-virtuos - Users / Technology partners
ISG 2014
- economic benefit -
ISG 2014
Conventional implementation (sequential workflow)
Engineering
Construction
Constructionspecific
focuses
CAD
FEM
MKS
Supply
Assembly
Machine / plant
not (yet) available
for implementation
Implementation
CNC, PLC
Implementation incl.
Factory Acceptance Test
Delivery
Production start
ISG 2014
Implementation phases
Implementation
CNC, PLC
Basic implementation
Approval
Technology optimization
Basic implementation
PLC functionality
CNC functionality
basic tests
Test installation/wiring
Test safety
User interface / HMI
control sequence
special functions
ISG 2014
Consequences of missed deadlines in the sequential workflow
Engineering
Construction
Supply
Assembly
IBN
Approval (FAT)
Technology optimization
Delay:
amendments
clarifications

Delay:
amendments
supply bottlenecks
corrections
Test / Safety
No more
delays are
possible!
Delivery,
Production start
Faulty compliance of customer specifications and deficient quality:

reworks on the customers premises during production start
additional unplanned costs and image damages
ISG 2014
VIBN Reduction of processing times and costs
Engineering
Construction
Supply
Assembly
CNC, PLC
Cushion for
optimisation
or
reduction of
delivery times
Real machine
required for:
installation test
technology
approval
Delivery
Production start
*1)
*1) Implementation times reduceable to up to 80% (empirical value of our best practice-customers)
ISG 2014
Fundamental economic advantages
Implementation time Reduction of up to 80%
shorter production times

reduced production hall occupancy
Software quality considerable increase with same manpower
test of regular and irregular operational states, HMI

performance can risklessly be increased by alternative processes
early bug-fixing saves follow-up costs
Risk minimization in project management
quality already achieved in the office

customer gets an early insight in the course of project
differing requirements are considered in time
Cost minimization during implementation on the customers premises
avoidance of collisions, malfunctions and process problems

endless test with virtual components and real production data
considerable shortening of connection to other automation systems
ISG 2014
10
HILS in control realtime
ISG-virtuos
- Hardware-in-the-Loop
in control realtime (1ms) -
ISG 2014
11

ISG-virtuos Requirements and basic principles of the solution (HILS)
Real machine
Real control
CNC
PLC
motion control
Economic process optimization

1. No extensive and non-conform
emulation of the control
functionality
use of real CNC/PLC
Fieldbus
2. Implementation (virtual) and

factory acceptance tests
without limitations
Virtual machine
for CNC/PLC, the virtual

machine behaves just like
the real machine
3. No parallel engineering /
simulation process
use of original engineering
data
ISG 2014
12

Why Hardware-in-the-Loop and control realtime?
PC operating system (MS-Windows)
real machine
real behaviour
real
controls
real fieldbus
fieldbus
(slave)
visualization
operation
realtime simulation kernel (solver)

m =
l ,ein W ,aus (l ,aus W ,ein )
W ,aus
ln( l ,ein
)
l ,aus W ,ein
120
4
simulation
PC
Dynamics
12
0.77
15
Logics
12.185
45 1
5 = 45
4 5
0.98
15
55 120
444 + 4
4 5
12
0.77
45
5
MF
Kinematics
15
4
realtime operating system (< 1ms)
The real / original control system can be used / tested without any changes
deterministic, realistic simulation behaviour just like the machine on the fieldbus
reproduceable model behaviour also after various simulation cycles for regression tests
manufacturer-independant, given the connection via established fieldbus systems
control configurations (incl. I/O addresses) identic to those on the original machine
ISG 2014
13

How does ISG-virtuos define control realtime?
Real-time classes and application areas (IAONA classification)
common
solutions
ISG-virtuos
building technology, control and

automation levels, trouble-free
processes, storage systems
conveying systems,
simple controls,
majority of all automated systems
machine tools, fast processes,

robots
highly dynamic processes,
electronic drives
1s
10s
100s
1ms
10ms
100ms
1s
10s
ISG 2014
14

TwinCAT 3 as the ideal platform for ISG-virtuos
Windows 32/64 bit
engineering / modell
test panel
3D visualisation
ADS - TwinCAT transport layer
real controls
real behaviour
dynamics
logics
EtherCAT
Profibus DP
Profinet
CANopen
FOCAS
SERCOS
MF
kinematics
Solver
TwinCAT 3
ADD TwinCAT device driver
real fieldbus
ISG 2014
15

One simulation system for multiple (various) controls
EtherCAT
Profibus DP
Various simulation / visualization scenarios

simulation PC with the possibility to connect multiple fieldbuses at the same time and thus multiple real
controls
multiple controls with multiple simulation PCs and one common visualization possible
automatic generation of a multi-slave configuration for the representation of control and I/O bus participants of
the control configuration
ISG 2014
16

Simulation of complex (distributed) automation solutions
SPS
SPS
CNC
fieldbus
SPS
SPS
CNC
CNC
fieldbus
CNC
main
computer
CNC
fieldbus
fieldbus
fieldbus
fieldbus
simulation PC
simulation system
manufacturing
cell
transport
dynamics
logics
dynamics
dynamics
main
computer
3D-visualisat.
plant, cell
simulation PC
simulation PC
logics
logics
kinematics
machine tool
kinematics
kinematics
simulation PC
fieldbus
junction of 3D simulation
Integrated test / simulation of complex automation solutions

simulation system easily expandable via fieldbus mechanisms
combination of Hardware-in-the-Loop-Simulation and real automation systems
superior 3D visualization of the complete plant
Factory Acceptance Tests already during implementation
ISG 2014
17

Module library reuseable component models
User / customer know-how setup / protection
proprietary library within the
scope of customizing
validated part- / sub models
efficient engineering owing to
reuse
real components
virtual components
Process optimisation in
engineering by automated model
generation
Solution- / Know-how library

ISG 2014
18

Module library reuseable models for 3D visualisation
3D CAD system
3D geometry library
3D visualisation
Virtual component store

reuseable components / assemblies for 3D models (direct import from CAD systems)
basis for module kit systems
comfortable generation of new configurations as well as adaption of existing components
Automatic 3D model generation based on the order-specific machine configuration
ISG 2014
19

Easy configuration process according to the machine configuration
ISG 2014
20

Removal simulation and collision detection / prevention
Removal simulation
precise, foto-realistic display
working progress in control realtime
Collision detection
definition of Krperpaaren
collision display and message
ISG 2014
21

Vast diagnosis and test functions
Diagnosis and test tools
(online):
displays, scanner, switcher, slider,
...
scope functionality in odrer to
show process data in realtime
performance optimisation on the
basis of recorded realtime data
tracking of process data
Provision of process data for
further processing in *.csvformat
ISG 2014
22
Engineering process
ISG-virtuos & TwinCAT 3

- Virtual implementation with
Beckhoff CNC / PLC -
ISG 2014
23
Engineering process
Implementation integrated platform CNC/PLC and ISG-virtuos
simulation PC
with ISG-virtuos
Beckhoff
CNC / PLC
Windows 32/64 bit
Windows 32/64 bit

I/OKonfiguration
I/Oconfiguration
control HMI
modelling
ADS - TwinCAT transport yayer
CNC
direct configuration
adoption
3D visualisation
(optional)
user interface
ADS - TwinCAT transport layer
dynamics
SPS
logics
MF
kinematics
realtime model calculation (solver)
TwinCAT 3 runtime
TwinCAT 3 runtime

EtherCAT
ISG 2014
24
Engineering process
Import of 3D geometry data
Engineering steps
import of 3D CAD data
visual control of results
optional model restructuring
generation of reuseable components /
assemblies
Engineering support
direct import from
CATIA, Inventor
NX, SolidWorks
Parasolid, STEP
VRML, IGES
filtering and optimising of 3D data

ISG 2014
25
Engineering process
Set-up of the kinematic model
Engineering steps
module organisation analogous to the
kinematic chain (variances)
model composition setup from modules
parametrisation and connection to 3D visual.
test by configurable control panels
Engineering support
vast module library with tailored kinematic
modules
simple use thanks to cut & paste sowie drag
& drop
no special know-how required
direct parameter transfer
ISG 2014
26
Engineering process
Modelling of machine functions funcional units (FE)
Engineering steps
organisation in functional units (FE)
with modular hierarchic structure
FE3
FE4
FE1
FE2
FE..
control input
control output
retract_axis
axis_retracted
FE
extend_axis
Causal loops between I/Os
attribution of control I/Os to the respective FEs
axis extended
Typical functional units (FE) of a BAZ
tool magazine
tool fixture
tool spindle
safety gate
tool fraction control
central lubrication, hydraulics, pneumatics
ISG 2014
27
Engineering process
Modelling of machine functions Realisation of causal loops (FE)
control output
control input
Engineering steps
construct causal loop with modules (library)
retract_axis
axis_retracted
assign the internal signals to the control in- and

outputs
extend_axis
axis_extended
define parameters
store as submodel in library
test FEs with respective control panel
Incoming test of
FEs by
controlling and
displaying
ISG 2014
28
Engineering process
Fieldbus connection protocols / configuration
Implemented fieldbus systems
real machine
fieldbus (EtherCAT)
EtherCAT
SW
Profibus DP
HW
Profinet
SW
CANopen
HW
Ethernet-IP
SW
safety functionality included
fieldbus components, slaves
(I/O and drives)
fieldbus components, multi-slave
(I/O and drives)
identical machine behaviour
virtual machine
ISG 2014
29
Engineering process
Fieldbus connection Generation of I/O configuration
Features / benefits
automatic generation of fieldbus I/Oconfigurations in ISG-virtuos (Multislave)
1.
2.
direct transfer of master configurations from

TwinCAT
resp. import of master configurations for Profibus-/
Profinet (*.cfg)
central I/O module in ISG-virtuos for all

required fieldbus I/Os
easily configurable mixed operation of real and
virtual fieldbus attendants via checkboxes
I/O configurations of various controls can be
combined
All required tasks are automatically instanced
as a TwinCAT project
ISG 2014
30
Engineering process
Fieldbus connection Connection between I/Os and simulation model
Features / benefits
connecting fieldbus I/Os and model via the
comfortable connect functionality
automatic provision of fieldbus I/Os (list in pop
up window)
one klick on the required I/O signal realizes the
connection
bit splitting for easy access on required
fieldbus information
Verbindung
I/O-Input/Output
cycle times for the fieldbus I/Os can be

parameterised flexibly (up to 1 ms)
Feldbus-I/O-Liste
engineering process can be automated via

XML-based interface (ecf- or csv-file)
ISG 2014
31
best practice solutions

ISG-virtuos in plant and machine construction (Fa. HEITEC AG)
Motivation / goal
short project life span
increasing variant variety and high changeover times
cost and time pressure
Use of virtual plant / machine for the implementation with

real controls
Visualisation of automation process in 3D
Main advantages User and operator

short implementation times and better SW quality
riskless test of also extreme situations
reuseability of mechatronic modules
generation of improved acceptance criteria
Optimisation of service and maintenance
Training and further qualification of personnel
ISG 2014
32
best practice solutions

ISG-virtuos for complex machining centres (BAZ) Fa. Grob / Daimler
Motivation / goal
BAZ for series production of motor blocks (2 tool
spindles, 2 tool magazines with 34 tools each)
productivity optimization subject to machine and control
technical components
optimisation of cycle times and professional handling of
failure situations
reduction of implementation times
Main advantages - manufacturer

considerably reduced implementation times
vast functionality test
Optimisation and test of alternative processes
Main advantages - operator

optimisation of cycle times (NC programmes)
collision control
personnel training without machine utilisation
ISG 2014
33
Implementation and test system

Beckhoff CNC and ISG-virtuos set-up of the implementation system
engineering and test panel
machine operation
3D visualisation
simulation scope (WOMAJET F2):

kinematics (X, 2xY / Gantry, Z)
safety clamp (4x EL1904, 4xEL2904)
EK1100
EL6900 (Safety-PLC)
safety drives (2x AX5805)

logics
Virtual machine control panel
EtherCAT
Component feed and extraction

tool: water jet abrasion
C6640-030
simulation PC
ISG 2014
34

Beckhoff CNC and ISG-virtuos machine operation
ISG 2014
35

Beckhoff CNC and ISG-virtuos Kinematics and abrasion simulation in 3D
ISG 2014
36

Beckhoff CNC and ISG-virtuos TwinCAT Device-PLC in realtime
ISG 2014
37

Beckhoff CNC and ISG-virtuos Simulation of machine behaviour
ISG 2014
38

Beckhoff CNC and ISG-virtuos TwinSafe applications
ISG 2014
39

Beckhoff CNC and ISG-virtuos TwinSafe simulation and test
ISG 2014
40
Integrated engineering platform

Our offer
TwinCAT 3 is the ideal platform for automation technology
project engineering with TwinCAT 3 is considerably facilitated by the
Automation Interface and the ECAD-Import
ISG-virtuos seamlessly completes the engineering support TwinCAT 3 by
adding the implementation of machines and plants with the original
control components and in control realtime (1ms)
Technical discussion can be intensified on the TwinCAT 3 and ISG-virtuos

test rig in hall 2 (D.04)
ISG 2014
41
Integrated engineering platform

Your ISG-virtuos contacts
ISG 2014
42
SINDEX 2014
Note
ISG 2014
43

ISG-Virtuos Sindex (2014)

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Implementation of a CNC machine with

ISG-virtuos SINDEX 2014

ISG-virtuos SINDEX 2014

ISG Industrielle Steuerungstechnik GmbH

Industrielle Steuerungstechnik GmbH

ISG-kernel (since 1987)

CNC, RC, Motion Control

control-, machine- and plant manufacturers

ISG-virtuos (since 2005)

virtual implementation (VIBN),

machine and plant manufacturers,

ISG-virtuos SINDEX 2014

ISG Industrielle Steuerungstechnik GmbH

ISG-virtuos SINDEX 2014

ISG-virtuos SINDEX 2014

ISG-virtuos SINDEX 2014

ISG-virtuos SINDEX 2014

Faulty compliance of customer specifications and deficient quality:

ISG-virtuos SINDEX 2014

shorter production times

Software quality considerable increase with same manpower

test of regular and irregular operational states, HMI

Risk minimization in project management

quality already achieved in the office

Cost minimization during implementation on the customers premises

avoidance of collisions, malfunctions and process problems

ISG-virtuos SINDEX 2014

HILS in control realtime

ISG-virtuos SINDEX 2014

HILS in control realtime

Economic process optimization

2. Implementation (virtual) and

for CNC/PLC, the virtual

ISG-virtuos SINDEX 2014

HILS in control realtime

realtime simulation kernel (solver)

l ,ein W ,aus (l ,aus W ,ein )

realtime operating system (< 1ms)

HILS in control realtime

building technology, control and

machine tools, fast processes,

HILS in control realtime

ADS - TwinCAT transport layer

HILS in control realtime

Various simulation / visualization scenarios

HILS in control realtime

Integrated test / simulation of complex automation solutions

HILS in control realtime

Solution- / Know-how library

HILS in control realtime

Virtual component store

HILS in control realtime

ISG-virtuos SINDEX 2014

HILS in control realtime

ISG-virtuos SINDEX 2014

HILS in control realtime

ISG-virtuos SINDEX 2014

ISG-virtuos & TwinCAT 3

ISG-virtuos SINDEX 2014

Windows 32/64 bit