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This article presents the results of applied research focused on the development of a hybrid software solution, which is based on the ABB RobotStudio 2021 suite, because even in the latest version, RobotStudio 10 does not have a dedicated virtual commissioning module. The aim of the study is to explore the potential communication capabilities between ABB RobotStudio and Siemens Simatic Robot Integrator and to unify control systems for performing virtual commissioning tasks. The proposed solution offers valuable procedures for any end user responsible for implementing robotic cell virtual commissioning tasks and ensures the compatibility between hardware and software components from ABB and Siemens manufacturers integrated into any robotic cell type. Siemens, one of the leading PLC manufacturers, offers the complex PLM platform Process Simulate, which can be integrated with the Totally Integrated Automation (TIA) Portal and Mechatronics Concept Designer (MCD) for developing virtual commissioning (VC) applications. The TIA Portal is recognized by robotics application integrators as the most efficient work environment for VC. However, there is currently no direct compatibility between the ABB RobotStudio (RS) platform and Siemens TIA Portal. To address integration challenges, Siemens has introduced the Simatic Robot Integrator (SRI) platform, which ensures compatibility with certain proprietary software from various robot manufacturers, including KUKA, Motoman, and Staubli. While Siemens has collaborated with manufacturers like KUKA and Kawasaki, major industry manufacturers such as ABB and Fanuc have yet to establish a standardized interface within the Siemens SRI platform. A mathematical model was also developed, which serves as a key perspective and a valuable tool for the future integration of double-portal-type robots into the working environments of ABB and Siemens. This integration aims to facilitate virtual commissioning in scenarios where such robots need to be implemented. Currently, ABB's library does not include double-portal-type robots, despite the fact that leading manufacturers of double-portal robot types utilize ABB's IRC5 controllers. [ABSTRACT FROM AUTHOR]

The design and commissioning of process systems involve complex procedures often guided by digital Mock-Ups, replacing physical prototypes. This study presents a comprehensive framework integrating Virtual Commissioning, 3D CAD modeling, and industry standards to enhance the design process of such systems, supporting first-time-right implementations. The methodology combines literature review, industry standards, and case studies from the feed processing industry. The framework emphasizes interoperability, data model integrity, simulation, and cross-disciplinary communication. Findings suggest a refined model structure for modern manufacturing complexities, with practical implications for industry practitioners. Future research should refine the framework and explore broader industrial applications, improving implementation processes. [ABSTRACT FROM AUTHOR]

In the era of digitalization, the practice to represent physical entities in the virtual world from a visual but also modelling point of view constitutes a significant enrichment for the related scientific research. Among leading technologies, virtual commissioning offers the chance to test, verify and validate the control system of a machine or, more generally, of a mechatronic system before the real start-up. Renowned benefits of virtual commissioning are the elimination of errors in a early design phase, as well as the risk reduction on the real start-up and the possibility to test real-case scenarios without any cost and in short time. Based on the development of the Digital Model of the machine or system in exam, virtual commissioning is hence often associated to the creation of Digital Twins, too. This work explores potentialities and limitations in the evolution of a virtually commissioned mechatronic plant into a Digital Twin. A physics-based 3D simulation software has been utilized for the creation of the kinematic model of the plant in exam. Outcomes of the study are twofold: the model is exploited to provide an example of a successful application of virtual commissioning; considerations regarding the evolution of the model into a complete Digital Twin are also drawn. [ABSTRACT FROM AUTHOR]

With the wide application of a new generation of information technology, remote technical services are receiving an increasing amount of attention in the manufacturing field. In view of the fact that most mechanical and electrical equipment manufacturing enterprises still need to send a substantial number of employees to the site to provide operation and maintenance services for customers, and the operation and maintenance costs of enterprises remain high, a remote operation and maintenance method of mechanical and electrical equipment based on digital twin technology is proposed. A digital twin remote operation and maintenance services model is constructed, and digital twin remote operation and maintenance technology is divided into four basic levels: virtual simulation, software/hardware-in-the-loop virtual commissioning, virtual and real synchronization, and cloud–end interconnection. With this, we conduct in-depth research on the key technologies involved in these four levels. The digital twin remote operation and maintenance service platform has been built; this platform can provide maintenance, repair, overhaul, and operation services for enterprise equipment. The feasibility of both the digital twin remote operation and maintenance services model and the digital twin remote operation and maintenance service platform was verified through cases, which provided an efficient and feasible solution for enterprises to improve service efficiency and reduce labor costs. [ABSTRACT FROM AUTHOR]

The article provides practical insights into the development of a specialized machine for automating the assembly of components based on customer-specified parameters. The initial design undergoes a risk analysis in accordance with the EN ISO 13849 standard, ensuring safety compliance. For the software aspect, we create sequences and algorithms for the machine's individual components using standardized formats within the TIA Portal software. To expedite programming and real-time debugging, a virtual commissioning approach utilising the fe.screen-sim program is employed. This allows us to address any issues or deficiencies in the virtual model, which mirrors the actual machine, optimizing the time needed for final physical adjustments. [ABSTRACT FROM AUTHOR]

To achieve interoperability between different 3D virtual commissioning software, a generic virtual commissioning data model is required. AutomationML is a standard neutral format for interoperability in the engineering phase. However, the current AutomationML standard is not sufficient for full-scope 3D-based virtual commissioning data exchange, as attributes and modeling method of 3D virtual commissioning-related sensors, actuators and signal connections are not standardized in AutomationML. To fill this gap, the authors suggest extending AutomationML for interoperability in 3D virtual commissioning. In this paper, a case-driven iterative approach is introduced to evolve towards an AutomationML extension. This extension is gradually developed by taking the union of all virtual commissioning-related functions and attributes of 3D virtual commissioning software. During the iteration, naming rules are applied when a new attribute is added to the extension. With this approach, an initial AutomationML extension is created by implementing a first iteration. The interoperability performance of this extension is subsequently evaluated by conducting data exchange of a representative set of 3D emulation models between two 3D virtual commissioning software, namely Siemens NX and Visual Components, via self-developed 'Import' and 'Export' plug-ins. It shows that AutomationML extension-based data exchange converts 70% more attributes than that only based on AutomationML. [ABSTRACT FROM AUTHOR]

Virtual commissioning (VC), defined as the simulation and testing of systems in a virtual environment before physical implementation, plays a key role in addressing the challenges of integrating and validating complex systems efficiently and effectively. This paper focuses on the topic of virtual commissioning, summarizing and organizing existing research in the field. The paper provides a comprehensive overview of various design methods and technologies currently in use. A case study of virtual commissioning is also presented within the area of the Cyber-Physical Manufacturing Systems Laboratory of the Széchenyi István University, detailing the solution steps taken. Drawing on both research and practical experience, the paper proposes a novel framework to support virtual commissioning design, referred to as the "Virtual Commissioning House" (VCH). The methodology is evaluated through comparisons with existing virtual commissioning solutions, demonstrating its effectiveness. [ABSTRACT FROM AUTHOR]

This article presents the results of applied research focused on the development of a hybrid software solution, which is based on the ABB RobotStudio 2021 suite, because even in the latest version, RobotStudio 10 does not have a dedicated virtual commissioning module. The aim of the study is to explore the potential communication capabilities between ABB RobotStudio and Siemens Simatic Robot Integrator and to unify control systems for performing virtual commissioning tasks. The proposed solution offers valuable procedures for any end user responsible for implementing robotic cell virtual commissioning tasks and ensures the compatibility between hardware and software components from ABB and Siemens manufacturers integrated into any robotic cell type. Siemens, one of the leading PLC manufacturers, offers the complex PLM platform Process Simulate, which can be integrated with the Totally Integrated Automation (TIA) Portal and Mechatronics Concept Designer (MCD) for developing virtual commissioning (VC) applications. The TIA Portal is recognized by robotics application integrators as the most efficient work environment for VC. However, there is currently no direct compatibility between the ABB RobotStudio (RS) platform and Siemens TIA Portal. To address integration challenges, Siemens has introduced the Simatic Robot Integrator (SRI) platform, which ensures compatibility with certain proprietary software from various robot manufacturers, including KUKA, Motoman, and Staubli. While Siemens has collaborated with manufacturers like KUKA and Kawasaki, major industry manufacturers such as ABB and Fanuc have yet to establish a standardized interface within the Siemens SRI platform. A mathematical model was also developed, which serves as a key perspective and a valuable tool for the future integration of double-portal-type robots into the working environments of ABB and Siemens. This integration aims to facilitate virtual commissioning in scenarios where such robots need to be implemented. Currently, ABB’s library does not include double-portal-type robots, despite the fact that leading manufacturers of double-portal robot types utilize ABB’s IRC5 controllers.

With the wide application of a new generation of information technology, remote technical services are receiving an increasing amount of attention in the manufacturing field. In view of the fact that most mechanical and electrical equipment manufacturing enterprises still need to send a substantial number of employees to the site to provide operation and maintenance services for customers, and the operation and maintenance costs of enterprises remain high, a remote operation and maintenance method of mechanical and electrical equipment based on digital twin technology is proposed. A digital twin remote operation and maintenance services model is constructed, and digital twin remote operation and maintenance technology is divided into four basic levels: virtual simulation, software/hardware-in-the-loop virtual commissioning, virtual and real synchronization, and cloud–end interconnection. With this, we conduct in-depth research on the key technologies involved in these four levels. The digital twin remote operation and maintenance service platform has been built; this platform can provide maintenance, repair, overhaul, and operation services for enterprise equipment. The feasibility of both the digital twin remote operation and maintenance services model and the digital twin remote operation and maintenance service platform was verified through cases, which provided an efficient and feasible solution for enterprises to improve service efficiency and reduce labor costs.

Abstract The benefits of advancements in information and communication technologies have proliferated in manufacturing applications as more industries are migrating towards industry 4.0 compliance. The industry 4.0 process lines should be dynamic and reconfigurable. Digital twin (DT), supported by real‐time data, is getting wide acceptance as a tool for monitoring and control of complex processes. Virtual commissioning (VC) has played a vital role in the software‐based validation of the control systems. A DT‐based VC methodology is proposed to evaluate and validate a reconfigured process line. The proposed new asset is commissioned virtually in the DT environment maintaining other stations and parameters synchronised. The proposed methodology is validated in a modular production system assembly line. A storage and retrieval station is virtually commissioned by the hardware in loop technique in the assembly line DT with a station time error of 1.3% between the VC model and the actual assembly line data. The case study demonstrates the feasibility of the proposed methodology in assessing the impacts due to reconfiguration of a process line. The findings offer significant support to decision makers in taking informed decisions and to reduce unforeseen interruptions resulting from the integration of a new asset with the existing process line.

Various software environments have been developed in the past to create digital twins of single cells or a digital twin of a factory. Each environment has its own strengths and weaknesses and has been designed with a specific focus. The environments that are able to holistically simulate complete factories are limited in terms of the modelling details required for the analysis of single manufacturing cells (e.g., manufacturer-independence of the individual digital twins) and their ability for virtual commissioning. This paper presents three options for realising a virtual commissioning of linked cells using a 3D integration platform with NVIDIA Omniverse, consisting of two different digital models fused into a combined model, also representing material flow. First, with a source/sink solution and unidirectional connector controlled by OPC UA; secondly, with a bidirectional connector, developed in the course of this elaboration, and an extension of the 3D integration platform controlled by Apache Kafka; thirdly, with a bidirectional connector and using only an extension of the 3D integration platform. The research demonstrates that virtually commissioning multiple linked digital twins from different manufacturers in a 3D platform with material flow makes a significant contribution to the industrial metaverse.

Increasing volatility in manufacturing and rising sustainability requirements demand more efficient processes in production, especially in employee qualification and engineering during development and on-site adjustments before and after the start of production. One possible solution is using digital twins for virtual commissioning, which can speed up engineering processes, qualify employees, and save valuable resources. To solve these challenges, it is necessary to identify promising approaches for using the digital twin and virtual commissioning. Furthermore, creating an environment where these approaches can be optimally explored is essential. This paper presents promising research approaches and demonstrates the development of an assembly process and a production system with a digital twin designed to explore these aspects. The presented system is an interlinked production system for assembling an actual industrial product. It includes different levels of human–robot interaction and automation, which can be implemented virtually in the digital twin.

Today, the verification of the control logic of automation projects is mainly a manual task during real commissioning phase on the physical installation. This involves a lot of risks towards possible damage and unanticipated delays in project completion. Virtual commissioning allows the verification to start earlier in the project timeline but is often also a manual task and requires a lot of human knowledge and expertise. This paper proposes a workflow to provide additional support to the automation engineer based on a 3D Digital Model that interacts with the real control logic. The digital model records all occurring states and transitions in the background and visualizes the state graph to highlight unexpected behaviour and to support troubleshooting. The proposed approach is validated on a test case confirming (1) the effectiveness of highlighting unexpected behaviour during programming phase and (2) the substantial reduction in real commissioning time. The added value of the approach is concluded, although a number of limitations still exist. Future research includes the validation of the approach on real industrial cases. [ABSTRACT FROM AUTHOR]

Various software environments have been developed in the past to create digital twins of single cells or a digital twin of a factory. Each environment has its own strengths and weaknesses and has been designed with a specific focus. The environments that are able to holistically simulate complete factories are limited in terms of the modelling details required for the analysis of single manufacturing cells (e.g., manufacturer-independence of the individual digital twins) and their ability for virtual commissioning. This paper presents three options for realising a virtual commissioning of linked cells using a 3D integration platform with NVIDIA Omniverse, consisting of two different digital models fused into a combined model, also representing material flow. First, with a source/sink solution and unidirectional connector controlled by OPC UA; secondly, with a bidirectional connector, developed in the course of this elaboration, and an extension of the 3D integration platform controlled by Apache Kafka; thirdly, with a bidirectional connector and using only an extension of the 3D integration platform. The research demonstrates that virtually commissioning multiple linked digital twins from different manufacturers in a 3D platform with material flow makes a significant contribution to the industrial metaverse. [ABSTRACT FROM AUTHOR]

[Objective] The significance of this study lies in the conversion of the traditional manufacturing industry into the intelligent, automated transformation of the background to meet the universities and colleges of intelligent manufacturing professional construction and cultivate urgent needs of the new era of composite technical personnel, to help students with the theoretical knowledge for the application of practical training, based on a solid foundation for the workplace, and to mitigate restrictions on the school laboratory space to cultivate diversified professional knowledge of the students. [Methods] In this paper, digital twin technology is applied to the intelligent transformation of the modular production system, thereby expanding the practical training content, relying on the "digital twin" virtual simulation technology based on Unigraphics, TIA Portal, PLCSIM Advanced, and other software, to conduct the virtual debugging training of the MPS digital twin model. The Process Simulate software and industrial Internet technology were used to conduct virtual and real linkage training, using intelligent monitoring technology for the real-time monitoring of equipment status, with the support of industrial Internet of Things technology to ensure the stability of data transmission and the safety of the experimental process during the training, reformulating the teaching framework, formulating the teaching plan for practical training in phases, and participating in the students' competitions. [Results] The teaching reform method of combining digital twin, virtual simulation, virtual-reality interaction, and other technologies with traditional equipment is proposed, and the MPS practical teaching platform is constructed, which integrates mechanical design, control system design, digital twin, and virtual simulation under the teaching platform, improves the comprehensiveness of the practical training teaching, imparts the equipment a higher utilization value while meeting the requirements of talent cultivation, and formulates a teaching framework for combining the content of practical training with college student competitions, which helps students receive several national awards. We have developed a teaching framework that combines practical training content with college student competitions, which has helped students bag several national awards and extended the breadth and depth of intelligent manufacturing practical training education. The application of equipment monitoring technology and industrial internet technology in practical training teaching provides strong support for the implementation of practical training teaching and provides a safe and stable experimental environment for the students. [Conclusions] Combining virtual and real considerably reduces the cost of improvement, effectively enhances the comprehensiveness, design, and research of the experiment, and improves the students' knowledge of the intelligent manufacturing engineering profession and industrial production, which is highly significant for the cultivation of intelligent manufacturing talents, and concurrently provides a new way of thinking for the reform of practical teaching in colleges and universities and the construction of intelligent manufacturing professions at present. The next step will be to further improve the maturity of the twin model and the degree of intelligence of the equipment to realize a higher degree of digital twins, cultivate more intelligent manufacturing applied talents, and provide a complete practical training platform for students. [ABSTRACT FROM AUTHOR]

Virtual commissioning (VC), defined as the simulation and testing of systems in a virtual environment before physical implementation, plays a key role in addressing the challenges of integrating and validating complex systems efficiently and effectively. This paper focuses on the topic of virtual commissioning, summarizing and organizing existing research in the field. The paper provides a comprehensive overview of various design methods and technologies currently in use. A case study of virtual commissioning is also presented within the area of the Cyber-Physical Manufacturing Systems Laboratory of the Széchenyi István University, detailing the solution steps taken. Drawing on both research and practical experience, the paper proposes a novel framework to support virtual commissioning design, referred to as the “Virtual Commissioning House” (VCH). The methodology is evaluated through comparisons with existing virtual commissioning solutions, demonstrating its effectiveness.

Presented in the paper is a virtual commissioning methodology for the design and verification of an OHT (Overhead Hoist Transporter), which is a vehicle that travels on the overhead track in a FAB (Factory for making semiconductor chips), and directly accesses the load port of the stocker or process equipment by the belt driven hoisting mechanism. Since the material flows of a FAB is extremely complicated, it is important to design the OHT control software by considering various situations. The proposed virtual commissioning methodology supports the full verification of the OHT control software by performing the simulation involving a 'virtual OHT model' and a 'real OHT controller'. We separate the virtual OHT model into two parts, a physical model (mechanical part) and a logical model (electrical part) to achieve the concurrency of mechanical and electrical designs of an OHT. Virtual commissioning identifies and addresses design flaws and operational faults so that significant savings can be achieved. The prototype of the proposed virtual commissioning methodology has been implemented and tested with several examples. [ABSTRACT FROM AUTHOR]

Increasing volatility in manufacturing and rising sustainability requirements demand more efficient processes in production, especially in employee qualification and engineering during development and on-site adjustments before and after the start of production. One possible solution is using digital twins for virtual commissioning, which can speed up engineering processes, qualify employees, and save valuable resources. To solve these challenges, it is necessary to identify promising approaches for using the digital twin and virtual commissioning. Furthermore, creating an environment where these approaches can be optimally explored is essential. This paper presents promising research approaches and demonstrates the development of an assembly process and a production system with a digital twin designed to explore these aspects. The presented system is an interlinked production system for assembling an actual industrial product. It includes different levels of human–robot interaction and automation, which can be implemented virtually in the digital twin. [ABSTRACT FROM AUTHOR]