Abstract
Industrial machines commissioning consumes a great amount of man-hours, due to control designers lack of knowledge about the final controller gains before they start working with it. Virtual commissioning has been postulated as an optimal solution to deal with this lack of knowledge when the Real-Time simulation of the digital models reproduces an identical behaviour as the industrial machines they represent. Cyber-Physical Systems (CPSs) offer new opportunities in this field, however, in the case of industrial machines, acquiring this level of accuracy requires to slow down the simulation. On this paper, novel modelling techniques for industrial CPSs have been presented. They are introduced to help in the evolution from conventional control design to a virtual commissioning process combining software and hardware capabilities. This methodology has been tested with a hydraulic-press model designed following manufacturer specifications, initially under a Software in the Loop (SiL) validation platform and, afterwards, in a Hardware in the Loop (HiL) validation platform. The control algorithms are designed in laboratory conditions harmless for the machine, embedding them later in the industrial environment without further modifications.
Highlights
Commissioning, as the last stage in any industrial machine design phase, consumes a great amount of man-hours [1]
DESIGN TECHNIQUES This paper presents a methodology to realize virtual commissioning based on a Hardware in the Loop validation platform, in which controllers are tested against a digital model of the system in a harmless environment
On this paper a novel methodology prepared to accomplish the virtual commissioning of industrial machines has been presented, sighting to reduce the associated costs
Summary
Commissioning, as the last stage in any industrial machine design phase, consumes a great amount of man-hours [1]. Rodriguez-Guerra et al.: Methodology for Real-Time HiL Validation of Hydraulic-Press Controllers the manufacture This leads to develop models capable of performing identical responses as the real machines, creating a Cyber-Physical System (CPS) of the industrial device [9]– [11]. The new technique sights for CPSs with Real-Time performance modelled at the system engineering level and capable of enough fidelity for virtual commissioning [17]–[20] It brings new benefits in the field of model design for industrial machines, as the set of equations defining the CPS are based on data-sheet information rather than complex physical properties.
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