Virtual Commissioning & Modular Simulation for Automation
Our MODUL4R experts at TTS Technology Transfer System S.r.l. have developed a comprehensive framework for virtual commissioning and modular simulation that integrates with IEC-61499 standard automation logic. This achievement advances industrial simulation capabilities by combining reusable simulation modules with direct automation system connections and real-time shopfloor data integration.
Technical Implementation
The core achievement involves developing a Digital Twin-based modeling system with polymorphic behavior through configurable profiles. This approach enables a single Digital Twin model to adapt across multiple simulation paradigms: Discrete Event Simulation (DES), Virtual Commissioning (VC), and data-driven shopfloor monitoring. The system utilizes a robust simulation framework enhanced with time-scanned synchronization capabilities, ensuring accurate coordination with external automation logic and sensor systems.
The framework's profile-driven architecture represents a breakthrough in simulation modularity. Each profile encompasses Java-coded behavioral aspects and comprehensive simulation configurations, including data source specifications and connection endpoints. This methodology enables rapid switching between operational modes without extensive model redevelopment, significantly enhancing development efficiency and reducing implementation timeframes.
Validation and Integration
The framework's effectiveness was demonstrated through the PCB assembly use case spanning two operational cells. Cell A manages capacitor handling and quality inspection, while Cell B handles component placement onto PCB boards. Independent development at different facilities (FFT and F-IWU) validates the framework's modularity and interoperability.
Real-time communication through MQTT protocol integration enables bidirectional data exchange between simulation environments and physical automation systems. The MQTT broker-centered architecture facilitates seamless communication between emulated controllers, simulation engines, web-based visualization interfaces, and monitoring systems.
Successful integration with Work Package 2 activities enabled comprehensive automation logic integration and shopfloor data incorporation, ensuring simulation models accurately reflect real-world operational conditions and control system behaviors.
Strategic Impact
These achievements establish foundations for accelerated industrial plant development throughout the entire lifecycle, from design through commissioning to operational enhancement. The reusable simulation module approach reduces traditional plant modeling time and effort, while integrated automation logic validation minimizes commissioning risks and costs. The framework's adaptability ensures continued relevance as automation technologies evolve.
