The "real" digital twin can only be created once there is a real counterpart. But Machineering has also developed a solution that can provide sustainable support for development even before real commissioning. The 'Field Box 1' provides system manufacturers with a residual BUS simulation for Profinet or Ethernet IP.

This field box forms the basis for a real-time simulation and can be used either on the desk or as a test rack with a connection to a real controller. Connected to the Industrialphysics simulation software, the Field Box 1 is simply connected to the computer or controller via Plug & Play and is immediately ready for use. "The big advantage over classic virtual commissioning is that no resources of the simulation computer need to be used for fieldbus emulation. The entire fieldbus emulation is performed externally in the field box. This eliminates the need for changes to the PLC, which previously also had to implement the ComTCP client," explains Dr. Georg Wünsch, founder of Machineering.

The second hardware innovation is the digital twin for the control cabinet, on which the virtual image based on real-time data can be called up at any time. The new 'Digital Twin' computer system from Machineering is also designed to simplify the entire work preparation process. "It can be used to supply the machine or its virtual counterpart with the real CAD data. All processes can be tested, run through, optimized or modified with the help of a simulation based on real-time data," says Wünsch. The new parameters are only transferred to the real machine once the virtual commissioning is running smoothly. Changeover times and the associated downtime are therefore reduced to a minimum.

Thanks to the high computing power (Intel Core i7 6700 TE with 16 GB RAM) and the high bandwidth (1 Gbit) to the machine controller, enormous amounts of data can be processed within a very short time, even without the machine having to be connected to the Internet with complex security measures. For example, collision models can be calculated and stored. The operator's production data does not leave the production hall, or only when the digital twin is read out for service purposes. "With the market launch of our Digital Twin, the operator does not have to allow a connection to the cloud for the time being, but can still benefit from all the advantages of the innovative Digital Twin technology," says Dr. Wünsch. "The Digital Twin can provide its own Wi-Fi and thus supply all common mobile devices such as smartphones or tablets with real-time data from the machine. It also serves as a basis for remote maintenance and predictive maintenance."