publications

The digital twin: a game changer in product development and commissioning

The digital twin is a much-discussed topic in mechanical and plant engineering. While some companies are still evaluating the theoretical application possibilities, others are already successfully using the digital twin in practice. This applies to virtual commissioning, for example. How designers, hardware planners, electrical engineers, PLC programmers, software developers and field service technicians can actually benefit from this is shown by the example of an engineering service provider that has implemented the technology in its day-to-day business.

The digital twin and its relevance in engineering

The digital twin is not only a core element of Industry 4.0, but also a significant innovation for engineering teams. This is because it fundamentally changes the approach to the development and commissioning of products. This is made possible by its core feature: the complete mapping of a real machine in virtual space with all its details and physical properties.

The team at blue automation GmbH is well placed to assess the specific advantages of the digital twin in practice. The service provider specialises in automation technology for the automotive, supplier, pharmaceutical and medical technology and food and beverage industries. The portfolio includes hardware design and PLC software development as well as robot engineering. From its many years of project experience, the Siemens Solution Partner knows that expectations and reality can diverge greatly in the traditional approach to product development: Processes do not work as planned, the software does not fulfil all requirements, the commissioning team has difficulties understanding, extensive mechanical changes are required or there is even damage due to a crash after the start. All of these problems can be avoided if a machine or system is first tested and optimised in a virtual environment.

Significant cost and time savings possible

The blue automation approach is structured in stages. Firstly, the customer creates the 3D data of the planned system based on the mechanical design. The provider then adds the physical properties of the machine using MCD. This is necessary in order to map the behaviour, movements and interfaces of all sensors and actuators. In the next step, the resulting virtual twin is ready to be tested virtually in conjunction with the PLC control system. Every function and the entire process can therefore be evaluated in detail even before the system goes into construction. Naturally, this results in a whole range of benefits.

Firstly, virtual commissioning using the digital twin is helpful for basic feasibility and achievability analyses. It also helps to identify and rectify design errors at a very early stage. Opportunities for material and energy savings also become visible. The quality of the associated software programmes can also be significantly improved through virtual testing. All in all, these features lead to lower costs for subsequent changes, more sustainable solutions and the delivery of an optimised product - both in terms of hardware and software.

Commissioning process is also significantly improved

In addition to cost and time savings as well as significant quality improvements, the digital twin has another major advantage: field service employees can familiarise themselves with the machine or system in detail even before they travel to the end customer. This is a clear advantage, especially for complex products. Virtual testing in advance means that the actual commissioning process runs much more smoothly. This in turn not only increases customer satisfaction, who naturally welcome a scheduled and problem-free go-live. Existing personnel resources are also spared considerably. In times when there is a shortage of staff and employees are generally less willing to travel, this is also a factor that should not be underestimated.
 

Further use cases for the digital twin

As the digital twin is available with 3D data, PLC and operating elements, it can also be used to train inexperienced or new operating personnel. Compared to training on the real system, this variant is completely risk-free, as operating errors do not lead to damage. Furthermore, various error scenarios, including the respective problem solutions, can be practised.

Of course, in practice it happens time and again that a running system needs to be converted or extended. This is another area where the digital twin comes into its own. This is because it makes it possible to plan and implement the conversion virtually, adapt the software and test the overall design. The real system is only modified once this has been successfully completed. This approach significantly minimises downtimes during the conversion.

Last but not least, the digital twin is a very good visualisation of the real system thanks to the 3D modelling. It can therefore also be used for advertising purposes, at trade fairs, for customer training or as part of demonstrations by the sales team.

Advertorial published in the Handelsblatt, 28/02/2024

IT/OT integration for smart machines: basics, challenges and prospects

There are two major areas of technology in industry: IT and OT. Anyone who succeeds in building a bridge between these two worlds can tap into considerable potential. But how can IT/OT integration for smart machines be realised?

IT and OT: two historically separate areas

IT (information technology) and OT (operational technology) fulfil different functions in industrial environments. IT focusses on network systems, the processing and storage of data in databases and the handling of information. It is based on highly developed programming languages and primarily supports administrative processes. OT, on the other hand, deals with hardware and software that has been specially developed for controlling machines and production systems. It uses electrotechnical systems and simple programming languages to control and monitor industrial processes. In the past, the two areas were separate. In the course of digitalisation, however, it became necessary to exchange data between OT and IT. This is particularly relevant for machine manufacturers and machine operators.
 

IT/OT integration for smart machines: relevance is steadily increasing

IT/OT integration for smart machines is becoming increasingly important in the industry. It makes it possible to combine the potential of both worlds in order to make production processes more efficient, flexible and sustainable. Three key interest groups are benefiting from this development in particular:

• Mechanical engineering companies: Especially in series and special machine construction, the ability to deliver ‘smart’ machines is a decisive competitive advantage. Smart machines can collect and analyse data from production processes and make it available in real time. This opens up new opportunities for machine manufacturers to create added value for their customers.
• Machine operators of older systems: Many production systems have grown over decades and are not designed for digital requirements. IT/OT integration opens up the possibility of retrofitting older machines with intelligent functions. By combining sensor technology with databases, these machines can be integrated into higher-level systems without the need for extensive new purchases.
• Machine operators with a focus on innovation: Companies that rely on technologies such as edge computing, artificial intelligence, predictive maintenance or OEE (Overall Equipment Effectiveness) monitoring can achieve significant optimisations through IT/OT integration. For example, it is possible to analyse machine data in real time and check for anomalies.

What possible applications result from IT/OT integration for smart machines?

IT/OT integration makes it possible to transfer sensor data from machines to a central database. There they can be further utilised in various ways. One option, for example, is real-time monitoring of parameters, i.e. condition monitoring. The ‘predictive maintenance’ concept goes one step further. Here, the recorded machine data is analysed using AI in order to detect anomalies that indicate a need for maintenance, an imminent fault or an impending failure. In such cases, targeted and early maintenance can then be initiated, resulting in minimised downtimes and reduced costs.

Energy monitoring can also be implemented thanks to IT/OT integration. The continuous monitoring of energy consumption data helps to identify ‘energy guzzlers’ and switch them off in a targeted manner. In this way, companies can not only reduce their operating costs, but also improve their carbon footprint.

IT/OT integration also makes it possible to monitor key production indicators such as availability, performance and quality in real time. Even older machines without integrated visualisation can be integrated into modern OEE monitoring systems using cost-effective retrofit solutions.
 

Challenges of IT/OT integration

• Despite the numerous advantages, the implementation of IT/OT integration for smart machines is associated with a number of challenges:
• Different standards and protocols: IT and OT use different communication protocols that are often incompatible. This technical hurdle requires specialised solutions to ensure smooth integration.
• Security and data protection risks: Every machine that is connected to the internet increases the risk of cyber attacks. Security measures such as firewalls, encryption and access controls are therefore essential to protect sensitive production data.
• Cultural and organisational differences: IT and OT teams often work with different focal points and methods. IT experts focus on software development and network security, while OT engineers ensure the physical function of machines. These differences can create communication barriers that need to be overcome through close collaboration and clear objectives.
   

This is where companies get support

Implementing a successful IT/OT integration requires specialised expertise and experience. blue automation GmbH from Rennerod, an expert in automation technology, offers comprehensive services that support companies in this field of activity.

The company is active in sectors such as automotive, pharmaceutical and medical technology as well as food and beverage. Its services include hardware design, PLC software engineering, robotics solutions, virtual commissioning and digital twins. Thanks to its interdisciplinary expertise, blue automation realises seamless IT/OT integrations for a wide range of machines.

Comprehensive know-how, for example in working with Siemens and Rockwell systems, enables the service provider to precisely implement individual requirements. blue automation guarantees quality, flexibility and safety at the highest level.

More efficient machine operation, cost reduction on many levels, more sustainability: there are many reasons to take a closer look at the topic of IT/OT integration for smart machines. Companies that need support in this area can contact the blue automation team at any time.

Advertorial published in the Handelsblatt, 11/12/2024