Simulation of Automated Systems

In the field of industry, simulation of automated systems is a solution increasingly used by companies, since one of the main objectives is to achieve automate processes as much as possible. For this, different ideas and options are searched, which allows, in the available space, to place new elements that facilitate work and improve production.

However, frequently, when implementing an automatization in the line, new circumstances and problems are found, which have not been taken into account until then. For instance, in industry, stopping the production of some line in a factory can mean large monetary losses, therefore, not anticipating the behaviour of automation can be fatal for a company. But, how can we anticipate as much as possible to real conditions of a production line? The answer is simulating the automated systems.

WHAT IS IT AND WHAT IS AUTOMATED SYSTEM FOR?

Simulation of automated systems consists of copying a real working environment – a factory, a laboratory or a production line – in a digital environment. In these simulations is possible to represent the movements made by the tapes, sensors, robots, AGVs and even people who are working.

Simulation of automated systems allows us to visualise quickly and easily the environment where the automation is going to be implemented. Also, in the simulation, the elements have exactly the same dimensions as reality, therefore, it is possible to know with precision the size that must have the automatization and how to pose it, when implementing it into the reality, having to make as few modifications as possible.

On the other hand, simulation times are adjusted to reality, then allows seeing better the improvement in efficiency depending on the elements of the automatization, as well as detecting bottlenecks during production.

A device which helps enormously to interpret a simulation of an automated system is virtual reality glasses. When a user puts on the glasses, he can “introduce” himself virtually into the simulation and see little details that can result in a problem in the future.

WHICH SOFTWARE IS MOST USED IN THE SIMULATION OF AUTOMATED SYSTEMS?

There is different software that allows performing simulations of automated systems. Among them, the most used are:

Process Simulate

Developed by Siemens, Process Simulate is specifically designed for the simulation of manufacturing processes, mainly in the industry of automobile manufacturing and the engineering of processes. It is used commonly to simulate and optimize production lines in the automotive industry, involving the planning and validation of the assembly processes. It offers specific functionalities for the simulation and validation of industrial robots, manipulators, and other equipment associated with assembly processes in manufacturing.

Plant Simulation

Like Process Simulate, Plant Simulation has been developed by Siemens. Meanwhile, Process simulation is specifically focused on manufacturing process simulation and offers specific characteristics to the simulation of assembly and robotics, Plant Simulation is a tool more generic that can be applied in diverse industries to module and optimize production systems and logistic processes.  It has a graphic interface, intuitive and easy to use focused on the simulation of manufacturing processes. It involves 3D capabilities for visualization. Its perspective of programming is based on graphics for programming and moulding.

FlexSim

FlexSim is used mainly for the simulation of discreet events and offers an intuitive graphic interface for its moulding, with capabilities of 3D simulation. Its programming allows for customization and extension using languages like Python. It applies to a variety of industries, including manufacturing, healthcare and logistics.

AnyLogic

AnyLogic offers a multimethod perspective that allows mixing the moulding of discrete events, and dynamics and based on agents in a single model. It can incorporate 3D elements for the visual representation of models and simulations. Also, it allows programming in Java, which gives flexibility. It is applied in diverse industries and has a free version for learning.

Which Elements Can Be An Automated System?

Some of the elements that can be added to the simulation of an automated system in the different Software are:

1. Production lines: Depending on the case, both the entire line and the workstations can be simulated separately. In the simulation, it will be seen how the different materials or compounds move along the line.
2. Robots: Robots are an essential piece of any automatization. In the software of simulation automated systems are models of robots of different types and brands that can be added to simulations. Also, kinematics can be attributed to them so that they move through space, grab things or leave them. In some Software like Process Simulate, the generated code of the kinematics can be downloaded and played on real robots.
3. AGVs: in the simulations, you can include AGVs that will move around the space and transform pieces along the line.
4. PLCs: Siemens Software (process Simulate and Plant Simulation) allows adding PLCs with code created from the TIA Portal and connecting the simulation with real PLCs. On the other hand, FlexSim and AnyLogic have their software that allows the PLCs’ behaviour.
5. Humans: Although work is still being done to make the simulation of humans and their movements as realistic as possible, nowadays there is the possibility of adding humans to the simulations of automated systems. In this way, it is possible to see the interaction of the workers with the different elements of the simulation.

Our Projects of simulation of automated systems

At ATRIA, we always try to be updated with new technologies that come out day by day. In some of our projects, we implement the simulation of automated systems to make sure that the automation to incorporate meets the requirements, of space as well as the reach of our clients. In this way, it is much easier to see the modifications that have to be made to the environment in which will be placed the automatization, and details that can affect in the future can be appreciated. Also, we calculate the cycle time and identify bottlenecks.

One of the projects in which we implemented a simulation of automated systems consisted of the study of one automatization in an assembly line. Thanks to the simulation, it was decided that the best automatization, considering the available space, consisted of two collaborative robots that grabbed different pieces and assembled them in the corresponding place. With Process Simulate, we were able to recreate the program of the robots to finally send it to physical robots.

Do you want to apply Simulation of automated systems in any of your projects? Contact us!