Leverage Virtual Design to Build a Better System

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Leverage Virtual Design to Build a Better System

Agenda
Discussion
Concurrent development of electrical, mechanical, and control systems
Operator Training systems
Studio 5000® Logix Emulate™
Virtual Design

Virtual Design
Increases design productivity and reduce risk with virtual design
Machine Prototyping Throughput Analysis Virtual Commissioning Operator Training Systems
Easily design and build next
generation machines with
confidence
Optimize throughput with simple,
real-time 3D simulation of
complex dynamic processes
Design, test, validate &
commission production lines and
new SKU’s before they are put
into service
Reduce risk and improve
operations by training workforce
in a safe, virtual environment

Hardware in the Loop (HiL)
Simulation of an industrial process interacting with physical
Logix5000™ controller.
Software in the Loop (SiL)
Simulation of an industrial process interacting with a Studio
5000 Logix Emulate™ controller.
Virtual Design Overview
Pros: Requires no hardware, scalable with minimal costs, ability to
manipulate speed of clock, easily synchronize for real-time simulation
Cons: Performance can vary from physical hardware
Pros: Exact performance regards to scan times, same
instruction set executed
Cons: Can’t manipulate speed of clock, requires physical
hardware and space, costly to simulate large systems
EtherNet/IP or TCP/IP
or RSLinx OPC

Emulation vs. Simulation
Emulation: Imitation of behavior of an electronic system with the help of another type of electronic
system/computer
 You emulate Controllers, I/O cards, servo drives, etc
Simulation: Imitation of behavior of the physical system with the help of a electronic system/computer
 You simulate process changes and behaviors, mechanical systems & physical reactions, etc
Depending on the needs, both Emulation
and/or Simulation are necessary
Studio 5000 Virtual Design
Process
Simulation
Equipment
Simulation
Control
System
Emulation

The Cost of Virtual Design (HIL vs SIL?)
 Even though virtual design can help to reduce costs and
time to market, the level of fidelity strongly affects the
cost equation
 Most systems can be simulated in parts or with a low
level of detail, making simulation viable and convenient
 High fidelity fully virtual simulation for large systems
might not be economically viable
 In many cases, the cost of the virtual design, although
high, is compensated and justified by savings in time and
other areas of the engineering solution
Cost Level of FidelityBasic Realist
Level of SimulationParts System
HiL
SiL
Emulate
Risk
There’s a compromise between the level of
detail and the cost of virtual design

Agenda
Discussion
Virtual Design

Architect Logix Designer View DesignerApplication Code ManagerStudio 5000® Logix Emulate™

Logix Emulate?
Emulation of
Logix5000™ controllers
• Run and test application code
without physical controllers
and Input/Output (I/O)
• Provides advanced debugging
to support code validation and
virtual commissioning
• Control execution speed to
identify potential issues
• Simulate discrete I/O
Emulation of
HMI applications
• Run and test FactoryTalk®
View SE/ME without having to
connect to a physical
controller
• 3rd party HMI applications also
supported via RSLinx OPC
New! Logix Emulate for Operator
Training
• Studio 5000 Logix Emulate™
for Operator Training provides
the ability to interface with
high fidelity process
simulators and Operator
Training Systems
• Snapshots, high speed data
interface, scan and time
control
What is
Simulate your system in a safe, virtual environment

Getting Started Is Easy
Access is similar to a physical controller
 Switch a project file between the emulator and a
controller
 Download the application to the emulator, just like
you would for a physical controller
 Emulate mimics the ControlLogix® chassis on a
personal computer
 Multiple controllers can be emulated on a single
computer
 A second emulated controller or 1789-SIM
module can be used to simulate I/O
 Data can be passed between controllers using
produce / consume tags

Consistent User Experience
If you can configure a Logix Controller, you can configure Studio 5000® Logix Emulate™
 Look and feel mimics a ControlLogix® processor
 Visualization of controller status
 Run, Program and Remote modes supported via soft key-switch
and/or Studio 5000 Logix Designer®
 Access configuration, properties and selections for:
 Single Scan mode
 Clear major faults

Code Troubleshooting Simplified
Break-Point / Trace-Point Capabilities
 Trace-point (TPT) – Provides the trace information when the appropriate
condition is detected
 Break-point (BPT) – Provides trace information and halts the application
execution
 Instructions are executed with application logic and trigger the operation
when the rung goes true

Configuring Studio 5000® Logix Emulate™
Simple, intuitive, easy-to-access configuration
Start, stop and adjust execution time
Configure tracing and when to
display the values
Access and display trace data
Configure time stamps
Access the trace log file location

Testing HMI Applications
Simulate Control Code and HMI Interaction all from a single PC
Step 1: Create Logix application and run in Studio 5000®
Logix Emulate™
Step 2: Create shortcut(s) in RSLinx® Enterprise for
the tags being tested.
Step 3: Map the HMI tag properties to the shortcut(s)
created and run the application to verify.

Agenda
Discussion
Virtual Design

Operator Training Systems
New interface provides tight integration with Operator Training Systems
Enables powerful operator training capabilities by connecting an emulated control
system to high fidelity process simulators
• Create a safe classroom environment for operators to
learn the system
• Enable more robust system testing to verify design
and implementations before commissioning
• Prove out process and/or system design changes
without impact to the running system
• Snapshot/Restore functionality enables the ability to restore
process to an instant in time for situational training
• Data interface provides robust mechanism to inject
simulated process control dynamics into the system
• Enables ability to halt/resume execution of the controller for
pausing a process
3rd Party Operator
Training Software
• Snapshot/Restore functionality enables the ability to
restore process to an instant in time for situational training
• Data interface provides robust mechanism to inject
simulated process control dynamics into the system
• Enables ability to halt/resume execution of the controller for
pausing a process
MYNAH

Operator Training System Interface
Reduce operator errors and identify control system errors before startup
 Enables ability to halt/resume
execution of the controller for
pausing a process
 Snapshot/Restore functionality
enables the ability to restore process
to an instant in time for situational
training
 Also used for
pre-startup validation
Process Simulation Software
Emulated Controllers
New OTS
Controller
Ensure that your team is trained and prepared for the unexpected

How To Get Started on Integration
OTS Vendor Integration Process
 If you’re an OTS vendor and would like to get in touch with Rockwell Automation
to establish an interface, please send an email to virtualdesign@ra.rockwell.com
 Rockwell Automation will establish an agreement with the vendor directly and
provide the necessary software and information to get started
 Current OTS Vendors that have established agreements with Rockwell
Automation Logix Emulate for OTS are:
 Please check our website: http://www.rockwellsoftware.com for additional
information and vendors as they become available
 Mynah – Mimic  Andritz – Ideas  Schneider - SimSci DYNSIM
 Cape – VPLink  Honeywell – Unisim

Agenda
Discussion
Virtual Design

Automation Productivity – Virtual Design
Engineering Cycle reduction from Computer Aided Engineering to a functioning plant
 Solidworks / Inventor / … for
design
 IndustrialPhysics for machine
and Hardware In the Loop (HIL)
simulation
 HoloLens for visualization
 Studio 5000® Logix
Emulate™ for developing
Machine Controller application
code
 Logix Control Systems on
EtherNet/IP.

VIDEO DEMO…

Agenda
Discussion
Virtual Design

Virtual Design
Increases design productivity and reduce risk with virtual design
Machine Prototyping Throughput Analysis Virtual Commissioning Operator Training Systems
Easily design and build next
generation machines with
confidence
Optimize throughput with simple,
real-time 3D simulation of
complex dynamic processes
Design, test, validate &
commission production lines and
new SKU’s before they are put
into service
Reduce risk and improve
operations by training workforce
in a safe, virtual environment

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Leverage Virtual Design to Build a Better System

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