Hybrid Digital Twins Using FMUs to Increase the Validity and Domain of Virtual Commissioning Simulations

Abstract

AbstractThe main objective of virtual commissioning is to help design and validate the control systems of entire production plants. Therefore, simulations on a logical and kinematic level are performed, typically in a Software- or Hardware-in-the-Loop configuration using the original control software and controller [1].However, the lack of level of detail means that this type of simulation is insufficient for an integrated system dynamics and control algorithms design. These engineering tasks are currently performed in separate tools, e.g. by finite element analysis, multibody simulations or by a combination, i.e. elastic multibody systems (EMBS) [2]. However, the designed components are only considered individually and not in the context of the control technology used. Therefore, primarily synthetic inputs are used and not the original control behavior. With a higher level of simulation detail, further questions about the system, such as the effect of control algorithms on the dynamic processes, can be virtually validated.Therefore, this paper explores hybrid component-based digital twins to combine the advantages of both VC and EMBS. Hybrid components allow the simulation of the interactions between process, machine and control system with a high level of detail where this is beneficial. Such integration is achieved using the Functional Mock-up Interface (FMI) to couple different simulation models in a co-simulation environment [3]. This is demonstrated in a simulation use case of an inverted pendulum. The level of detail of individual components in the virtual commissioning tool ISG-virtuos [4] is increased by the modular integration of elastic multibody simulations via FMI so that the swing-up controller can be designed in the simulation.