< Previous18PERSPECTIVESAWJANUARY 2020software, Simatic S7-PLCSIM Advanced, which enables realistic simulations of con-trollers without the real hardware, and the Totally Integrated Automation (TIA) Portal, a digital framework for mechanical and elec-trical design and automation engineering to test and identify failures before commis-sioning takes place.Testing machine functionality on a digital twin is a dramatic change from the way most OEMs test the design of a machine, which is by building a physical model of it. But when something fails on a physical prototype, it is a very expensive error.“Error-related cost will increase by a fac-tor of 10 as you go from one value-added level to the next,” says Colm Gavin, digita-lization sales specialist, factory automation at Siemens, speaking about the digital twin during an Innovation Stage presentation at PACK EXPO Las Vegas 2019. “But if you are sitting at a desk [working] in CAD and you find a mistake, it is cheap to fix it quickly.”In addition, the Siemens technology takes simulation a step further by tying it to the automation system which may include vir-tual programmable logic controllers (PLCs) and human-machine interfaces (HMIs), thereby allowing the engineer to emulate how a machine will react in a variety of cir-cumstances. The real advantage here, Gavin says, is a communication application pro-gramming interface (API) within TIA Portal that guarantees synchronous communica-tion between the model and the PLC to sim-ulate everything within the model, including programming and debugging.“Many people will say a [virtual] PLC doesn’t do it, but in our case, we download a one-to-one match of what will go into the real PLC later,” Gavin says. “You are not forced into using the real hardware con-nected to the modeling software.”For machine builders, this means there is more flexibility in the design and com-missioning of products because the digital twin provides a riskless way to test differ-ent designs.“Innovation is painful because the only way to learn is to fail,” Hjertaas says. “By introducing this virtual model, a digital twin of our machine, we can do all of our failing faster and do it virtually, which is cheaper. By putting data into the same model, we can learn from that and see things we need to improve on prior to building the machine.”These are the digital daysTechnology is heading in a highly-automated direction. To that end, there’s a phenom-enon that Gartner is calling “hyperautoma-tion,” which the firm rates as number one on the “Gartner Top 10 Strategic Technol-ogy Trends for 2020” report. According to the research and advisory company, hype-rautomation deals with the application of advanced technologies, including artificial intelligence (AI) and machine learning (ML) to increasingly automate processes and aug-Design a Conveyor in Minutes!Using Dorner’s Online Configurator,you can design a conveyor for your application. 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Its outstanding oil resistance (Oil Res I/II) guarantees a long service life for industrial applications in dry, damp and wet environments.ROBOTICSFOOD AND BEVERAGECHEMICALAUTOMATIONEVENT, THEATER & LIGHTINGTRAYCONTROL 550 TPEMATERIALHANDLINGPERSPECTIVESAWJANUARY 2020ment humans. It’s a combination of tools that, while not the main goal, will often result in the creation of a digital twin of the organization (DTO), propelling real-time, continuous intelligence about the organization and driving new business opportunities.For OEMs, hyperautomation is coming in the form of model-based machine development. And technology suppliers are stepping up with new offerings they think will drive widespread adoption.This past August, B&R Industrial Automation announced that it has integrated the industrialPhysics 3D simulation tool into its Automation Studio engineering environment. This will enable developers to import CAD data from machine components to entire machines directly into the simulation tools to generate a digital twin for developing and testing the machine. Because the simulation tool is integrated with Automation Studio, developers are able to run the virtual model of the machine on the PC and connect with the controller. This makes it possible to view the physical behavior of the machine in real time, such as simulating the flow of materials through a line to identify potential colli-sions, which can be fixed in the digital model.B&R includes many variations of simulation tools in its product portfolio, all with the goal of shortening design cycles to acceler-ate time-to-market. A partnership with Maplesoft, for example, has resulted in the B&R MapleSim connector, which creates a simplified workflow between the system-level modeling environ-ment (MapleSim) and the automation design environment (B&R Automation Studio). This connector allows designers to create their digital models and test their PLC code in the same workflow.“Now you can play in a virtual sandbox environment where mistakes are free,” says Derrick Stacey, product owner, port-folio management at B&R. “Which is nice when you are trying to be innovative.”B&R knows a little something about innovation with its devel-2001_Perspectives.indd 202001_Perspectives.indd 201/20/20 1:17 PM1/20/20 1:17 PMCount-down to the New Year and count on LAPP’s ETHERLINE® industrial ETHERNET solutions. Our full range of CAT.5 to CAT.7 Industrial ETHERNET (IE) cables are designed to withstand impact, EM/RF interference, flexing, torsion, and temperature extremes. Our range of cable and connector options provides secure, reliable, real-time in-dustrial communication across multiple protocols — delivering flexible, scalable options for growing, complex industrial networks. Future-proof your factories for many New Years to come with LAPP’s ETHERLINE® IE connectivity solutions. Count on LAPP ETHERLINE®to keep your factory up and running ...the ball does.29 Hanover Road, Florham Park, NJ 07932 800.774.3539 — LAPPNA.COMball dropCourtesy ofLAPP ETHERLINFull Page Ad.indd 73Full Page Ad.indd 731/20/20 12:08 PM1/20/20 12:08 PM22PERSPECTIVESAW JANUARY 2020opment of AcoposTrak, an intelligent track system that uses independently controlled shuttles and electromagnetic diverters to divide and merge product flows at full pro-duction speed. In an effort to prove out the technology to OEMs and end users, B&R is using digital twin technology to config-ure and reconfigure adaptive machines—ensuring the equipment meets customer requirements right away.B&R uses simulation to show people what track systems can do. And, in fact, Stacey has been able to demonstrate to customers that they are putting in too many shuttles for the application, for example. That not only saved them money and space, it also provided them with a full understanding of what they were getting before committing to a purchase order.In fact, the integration of industrial phys-ics simulation into its Automation Studio makes it possible to view the AcoposTrak digital twin using virtual reality or aug-mented reality headsets. With virtual reality, processes can be evaluated with simulation running, and with augmented reality, the OEM or end user is able to view the model on-site in the real environment.“With the digital twin, seeing is believing, which helps open a lot of doors as far as questions and answers go, and the back and forth between the supplier and the OEM,” Stacey says.Siemens’ Gavin agrees that simulation—even on a virtual HMI—can change the understanding of how the machine will run, which could even influence the sales pro-cess. “How does an OEM sell a machine today? A photograph? If you take a digital twin to customer and show them what it will do, they can get a better understanding of what they will get and if works with their requirements.”Commissioning the latest creation It’s during the deployment of a machine when most of the controller programming is done, getting tweaked and modified to meet unforeseen circumstances on the plant floor. Understanding this is a major pain point in equipment commissioning, Rockwell Automation, too, has made a move toward digital twin technology.Last January, Rockwell acquired Emu-late3D, a UK-based developer of simulat-ing and emulating software for industrial automation systems. A sweet spot for the company is material handling in packaging. For OEMs, the product Emulate3D Controls Testing for Machine Builders helps create controls testing models on a wide range of machine types, directly within Dassault Systemes SolidWorks 3D design software. The tool allows users to design the machines or mechanical system in CAD, mark up the kinematic and control elements, add a load source if the operation is triggered by the presence of products, then connect the 248-295-0822Visit www.Acromag.com/spTO LEARN MORE■USB configuration■DC and temperature models■One input, two outputs■Optionally scale inputs differently for each outputRemote I/O solutions that you can depend on.ProgrammableSignal SplittersDeliver Precise Scalingof I/O Ranges2001_Perspectives.indd 222001_Perspectives.indd 221/20/20 1:17 PM1/20/20 1:17 PMwww.automation24.comWith us you are in the right place!Your online supplier for automation technologySensor systemsMeasuring & regulation technologyControl systemsIndustrial commucation technologyDrive technologyIndustrial controlsCircuit protectionSwitches & signaling devicesWork toolsConnecion technology Enclosure /Control cabinetsHIGHQUALITYIN STOCKPRODUCTSEXCEPTIONALPRICING$SUPPORTFREEAPPLICATION2 YEAR100%MONEYBACK100%GUARANTEE90 DAYSOVER$50SHIPPINGwww.automation24.com – your online supplier for automation technology800-250-6772 (toll-free) or 610-981-2900mail@automation24.comwww.automation24.comPower supplyIndustrial lightingAutomation24offers a full range ofindustrial automation technology solutionsFull Page Ad.indd 73Full Page Ad.indd 731/20/20 12:10 PM1/20/20 12:10 PM24PERSPECTIVESintegratIT-OT Data865-251-5252sales@softing.uindustrial.softing.com/ustManager in-chassis connectivity for CompactLogix PLCsWhyconnect CompactLogixtoSQLDashboards,nalytics,MES,TrackTraceConnectingproduction linestoenterprise dashboardshas never beeneasierDigitaltransformation withnocoding,noserver,noprotocol translationtManagerisanin-chassis SQLclientgenerating Inserts,Updates,Selects, andcallingtored roceduresScantheQRcodetofindout what'sbetweenCompactLogix andyourSQLdatabaseVisitindustrial.softing.com/en/tManager-compactlogixtManagerisanin-chassisSQLclientforCompactLogix. EliminatetheserverinthemiddleandeliminateOPC protocoltranslationinthemiddlewiththeeasiestway toconnectCompactLogixtoSQLdatabases!tManager®AWJANUARY 2020control and activation elements to the PLC I/O and run the emulation model.According to the company, by combining mechanical CAD information with real control system logic, you can create a valuable testbed in the form of a dynamic digital twin. This changes design and commissioning from a linear path to a parallel approach. “As soon as the system is designed you can start developing and testing the control system,” says Ian McGregor, business development manager at Emulate3D by Rockwell Automation.The tool is based on a precise mathematical model. A capability the company calls Aspects adds functionality to the CAD model. Aspects are properties that inform the runtime environment of the behaviors associated with the CAD element. Aspects associ-ated with material handling models, for example, might include collision geometry physics types (such as box, mesh, sphere, cylinder, etc.), kinematic joints (such as hinge, slider, etc.), or movement surfaces like conveyors.“When you mark something up in a particular way, we can look at other things marked up and make algorithmic decisions of how it will all work,” McGregor says.The future is nowMaking a digital twin of a machine might seem like a reach for many OEMs—and perhaps it is even unnecessary. But as the digital trajectory continues across the enterprise and plant, manufacturers will soon be demanding that OEMs supply a digital twin as part of a standard order. So, now is the time to get ahead of it and start on a small scale to understand the workflow, technology suppliers say.“A digital twin is something many end users are thinking about, but not something the machine builders are doing yet,” says John Kowal, director of business development at B&R. But it is some-thing OEMs will have to consider. “Just like when the industry went through lean manufacturing or vendor managed inventory, this is another tool to be more efficient and to differentiate your company in the marketplace.”Siemens’ Gavin echoes that thought: “End users will start expecting digital twins from their machine builders, and the ones behind on this will be left behind for sure.”And once an OEM starts using the digital twin, it opens up new opportunities—think innovative R&D, virtual factory acceptance tests (FAT), asset lifecycle management, and end user training. And it also becomes integral to the digital enterprise. At Tronrud, the digital twin is now a part of the way they do business.“I see the digital twin as a natural part of our everyday work,” says Hjertaas. “We put data from real life models back into the virtual model to simulate things that could happen in operations, so we have to use this every day, and we will continue to. We can’t predict the future, but when there is data available from a machine digitally, we can use that to make the machines even better.”2001_Perspectives.indd 242001_Perspectives.indd 241/20/20 1:17 PM1/20/20 1:17 PMAs easy as that.Rely on the highest torque regulation performance in the market to increase your Flow-wrapper’s uptime, while reducing engineering time with our Smart Servo Axis solution.Are you looking for the highest degree of regulation from the wrapping application in your machine utilizing the very thinnest films?Visit us at MODEX 2020 | March 9-12 | Booth #4419 | Atlanta?Full Page Ad.indd 73Full Page Ad.indd 731/20/20 12:10 PM1/20/20 12:10 PM26AWJANUARY 2020PERSPECTIVESHardware Meets SoftwareYOUR PARTNER FOR INDUSTRIAL COMMUNICATIONHMS-NETWORKS.COMCustomized manufacturing is a major trend across all manufacturing verti-cals—from food and beverage to auto-motive. But the industry vertical that has likely been impacted most by this trend is electronics.From memory to processor speeds to the amount and type of connection ports, the number of commonly available options on a consumer electronics product typically trans-lates into hundreds of possible assemblies for the manufacturer. Now consider information technology (IT) electronics, such as servers, and the amount of configurability offered by suppliers of these technologies to address various business demands. That’s the level of complexity faced by Foxconn on its production lines in the company’s Kutna Hora, Czech Republic, facility which produces HPE (Hewlett Packard Enterprise) IT systems.To give you an idea of how complex assemblies can be at this Foxconn site, consider that one HPE server model can be equipped with between two and sixteen memory modules, each of which can be 16, 32, 64, or 128 gigabytes. “These memory options allow for several hundreds of product variants—and these, in turn, must be multiplied with the number of options available for the processors, fans, disk drives, etc.,” says Norbert Reil, director of global IoT services, HPE Pointnext (the com-pany’s digital transformation consultancy).Foxconn Upgrades Quality with Video AnalyticsBy David GreenfieldDirector of Content/Editor-In-Chief 2001_Perspectives.indd 262001_Perspectives.indd 261/20/20 1:17 PM1/20/20 1:17 PMFull Lifecycle Support Partnermavtechglobal.com888.917.9109Talk to aProcessAutomationExpert.mavtechglobal.com/full-life-cycle-support/Process AutomationDCS MigrationStartup & CommissioningOperational ConsultingSustaining ServicesEnterprise IntegrationLEARN MOREFull Page Ad.indd 73Full Page Ad.indd 731/20/20 12:38 PM1/20/20 12:38 PMNext >