The creation of system layouts is a creative process, especially in the concept phase. The aim is to develop structures that are as efficient as possible for given objectives, often in a limited space. This is where Emulate3D comes in and allows the creation of 3D plant layouts within a very short time on the basis of highly parameterizable modules. In a subsequent step, movements of machines, robots, conveyor and storage technology, workers, automated guided vehicles and material flows, for example, can be added. This creates a dynamic digital twin of a planned or existing system. Emulate3D is therefore often used in sales phases, for example when a possible solution needs to be presented to a customer and discussed.
Advantages / Benefits
of a digital twin for layout planning and visualization based on Emulate3D
Time Saving
- Parameterizable blocks
- Predefined dynamic behaviour of the blocks
Interaction
- Model adaptations within a very short time
- Use in workshops
Communication and Presentation
- Solutions directly on the 3D model
Video fly-throughs
Virtual walk-throughs (VR glasses)
Presentation using AR
Creating an Understanding of the System
- Detailed 3D models
- Representation of material flows and movements
Identification of Planning Errors
- Geometric overlaps and collisions
- Analysis of solutions using virtual and augmented reality
Professional Appearance
- Presentation of solutions based on digital twins
- Virtual system inspections using virtual reality
Higher Quality Planning
- Support of the planning process through interactive 3D planning
Increased Project Completions
- Creating understanding and transparency
- Increased communication and confidence building
Video about the software
Layout planning and visualization with Emulate3D
In the course of the engineering and design phase, machines and systems are constructed and designed with regard to predefined performance targets. In this process, static analytical methods such as classic Excel calculations are generally used, which, although they are fundamentally justified, cannot take dynamic factors into account. As a dynamic process simulation tool, Sim3D enables this and considers machines and systems in their interconnection with stochastic elements, e.g. for machine availability or process times. The informative value regarding the correct design of the system and the expected performance is thus many times higher and prevents systems from being put into operation and falling far short of the projected performance.
Advantages / benefits
Of a digital twin for process simulation based on Emulate3D
Time saving
- Determining system performance and expected overall availability
- Bottleneck analysis, problem areas in the material flow
- Sensitivity analyses
Quality / Stability
- Development and validation of control strategies for smooth operation
- Evaluation of alternative solutions
- What-if scenarios
- Investigation of fault scenarios
Cost savings
- Correct dimensioning of system components, e.g. necessary buffer sizes, number of robots, vehicles
- Early identification of errors
Video about the software
Process simulation using Emulate3D
Historically, the commissioning of automated systems has taken place over a long period of time on site at the construction site or at the machine. This makes the commissioning phase time-consuming and cost-intensive due to travel costs and the need for testing. In addition, the willingness of commissioning engineers to travel has decreased significantly and at the same time the demands on project lead times have risen sharply. Emulate3D addresses this problem and enables the virtual commissioning of control systems at an early stage and in parallel to other engineering, production and assembly processes on the basis of dynamic digital twins. This applies both to PLC control systems (hardware in the loop, software in the loop) and to superimposed control systems such as material flow computers. Emulate3D thus helps to reduce both project costs and project risk. Systems go into operation on schedule and run with high availability.
Advantages / Benefits
From a digital twin for virtual commissioning based on Emulate3D
Risk reduction
- Earlier tests possible
- Detection of crash situations
Quality
- More extensive software tests possible
- Test of normal operation and error situations
Cost savings
- Reduction in time on site
- No physical test operation necessary
- Reduction in production downtime for brownfield and retrofit projects
- Virtual instead of physical prototypes
Video about the software
Virtual commissioning with Emulate3D