I would be interested to hear the experiences from those who uses virtual commissioning to test PLC code prior to actual commissioning.
We use a system called WinMOD, where the machine / line is modeled in 3D and to scale. Sensors, safety devices, etc. are added to the model as they would be on the actual line. As the system is to test the completeness and quality of the PLC code, hardware such as VFD's are substituted using macros that replicate the actual functions and connections they are emulating. The PLC I/O is assigned to the emulated hardware and line sensors. Once completed, the PLC is connected to the PC running the 3D model and associated software. An emulated control station & HMI can then be used to run the line, as if it were the actual line.
The PLC / HMI software is tested through normal and abnormal conditions, faults simulated and recovered. Software issues can be resolved and fault recovery simplified. The line can be left running for a number of days to test the robustness of the PLC code. All this prior to the actual commissioning.
Whilst the VC process can appear to add significant cost to the project, actual commissioning time will be reduced and subsequent downtime from software bugs should be eliminated. If done correctly, a digital start up should be possible, hence achieving an overall cost reduction. VC is not for every automation and controls project, cost analysis is needed to ensure that it is cost effective for the project.
3D Model of a production line.
Kind regards,
Jon
