Virtual plants in machine automation research and development

Computational product development has become the mainstream methodology in modern product development. The same trend has been visible also in research, where computational methods have gained popularity beside the traditional approach relying on theory and experimentations. The objective of this project task was to study and demonstrate a realistic approach for an industrial case to reuse existing mechanical design CAD model as the starting point and the template for mechanical system simulation using multibody system simulation, and to use this MBS model as a virtual test plant for automation and control system testing. In the report, the role of system modelling and simulation in the product process is first dis-cussed and some selected technologies, such as Modelica simulation language and Functional Mock-up Interface specification, are introduced. Then different possible implementations approaches for a test environment of the control and automation system of a multi-technical system are discussed. The latter part of report focuses on describing the selected approach for a demonstration system and its implementation. The demonstration showed that, at least for the selected case, modelling, simulation and post-processing of a multi-technical simulation system is relatively straightforward and fast with the selected tools. The demonstration gives some understanding of the process for implementing one relatively small multi-technical system but does not give realistic feedback about the challenges in industrial-scale process for virtual prototyping of large and complex systems and related data exchange and data management.