Simulation and digital twin
Using digital technologies to evaluate the logic of our automation solution, simulation and emulation are employed.
Simulation and emulation are important tools for Qubiqa because they allow our engineers and designers to test and evaluate the performance of a machine before it is built.
This can shorten the time and expense involved in creating and testing prototypes, assist in detecting and fixing design flaws, and optimize the design for effectiveness and efficiency.
Both simulation and emulation can be used to optimize the design of a machine, reduce the time and cost of prototyping and testing, and improve the reliability and performance of the final product. They can also be used to train operators and maintenance personnel, as well as to develop and test control systems and software.
There are also certain limitations in terms of Mechanical/physical testing of things like slippage, foils, etc. Not everything can be tested virtually to the level required, so the physical FAT is still needed.
What's the difference?
Simulation
With virtual PLC
Simulation involves creating a virtual model of a machine or system and using computer software to simulate its operation and performance under different conditions. This can be used to test and optimize the design, as well as to predict how the machine will perform in the real world.
Emulation
With hardware PLC
Emulation involves creating a model of a machine or system using hardware components, such as microcontrollers and sensors, that can be controlled and monitored using computer software. This allows engineers to test and debug the machine in a controlled environment, as well as to evaluate its performance under different operating conditions.
Potential benefits of simulation and emulation
- Calculate flow/capacity easier in the sales phase
- Test the software logic during the design phase
- Virtual FAT (not depending on component lead times)
- 50% faster ramp-up time during commissioning
- Less implications after SAT
- Virtual operator training incl. fail scenarios
- Cheaper development of new machinery and software
Machinery
We often experience that our clients have specific requirements of how we should program the machinery we deliver. Therefore, it is important that we test the software before we install it. Emulation then can be used to test software that is designed to run on a specific operating system or hardware platform. By emulating the target environment, we can ensure that the software functions correctly before deploying it on the actual machine. In this specific case we have done development of a new mechanical solution for a packaging machine which the client wished to have emulated. This includes both performance and security testing of safety functions. This also allows us to deliver a virtual environment that our client can use for training purposes.
Conveyor system
Simulation/emulation can be particularly useful for testing conveyor systems because it allows engineers to test the system’s behavior under a wide range of conditions and scenarios without setting up all of the components for a physical FAT. Emulation can also be useful for identifying and troubleshooting problems with the conveyor system, as it allows engineers to simulate and analyze the system’s behavior in detail, helping them to identify the root cause of any issues and develop solutions to fix them. In this specific case we actually both had a virtual as well as a physical FAT.
Digitalization is important for us and we strive to be forefront with knowledge and technologies.