Speyer, September 04, 2024 – The digital twin is in danger of falling short of its potential. New approaches are needed to do more than simply simulate systems. Systems need to be opened up and creatively connected. SpiraTec is taking this approach and using the digital twin for the virtual commissioning of systems – with applications extending deep into the field level and far beyond pure visualization. In this interview, experts Michael Kasseckert, Team and Account Manager at the SpiraTec site in Erlangen, and Viktor Gaponenko, Senior Software Engineer, explain what this looks like in practice, why gaming technology plays a decisive role in this and how SpiraTec AG intends to use swarm intelligence in the future.
Digital Twin can do more than just simulate systems and processes. How does SpiraTec use the virtual models?
Michael Kasseckert: We focus on virtual commissioning and process simulations are simply not enough. In order to map the industrial behavior of machines and systems, we go many steps further down to field level. Our virtual models are therefore fundamentally different from pure visualization in 3D. With our approach, we enable a direct link to real control systems. By connecting everything down to the system’s sensors and drive technology, we offer a realistic test environment in which processes can be displayed in real time and even adapted or changed.
What is also exciting in this context is that although we deal with the bits and bytes of the system at a very high level of detail, scalability is still possible – this means that even very large systems or, for example, an entire hall of a high-bay warehouse can be mapped in real time.
What is the challenge?
Michael Kasseckert: This approach is only possible if you combine the right technologies. There is the level of pure simulation of processes – but this is not enough to carry out virtual commissioning. A second level must be created on which the control of the system can be simulated. Connecting these two levels and making them talk to each other is the challenge – this is where our expertise lies. SpiraTec has many years of experience in the implementation and support of virtual and real commissioning as well as the development of behavior models in the appropriate technology environment.
At the simulation level, technologies are used that originally come from the gaming sector. Two worlds are merging here that seem very different at first glance. How can the industry benefit from this?
Viktor Gaponenko: The gaming industry currently provides the most modern and best technologies for creating 3D worlds, including shadows, textures and light reflection. These technologies are widely available and comparatively inexpensive. It therefore makes sense for the industry to use tools such as Unity to create virtual models and make them look as realistic as possible. If we use these technical possibilities opened up by game development for visualization and combine them with automation software such as TwinCAT, a virtual image of reality is created. So realistic that the connection to the PLCs creates a test environment in which changes can be made in real time.
The advantage: the automation software can be virtually tested and fine-tuned before the system is built. This leads to higher productivity, significantly improved software quality, less downtime and lower costs.
What does this look like in practice? Are there any specific projects at SpiraTec AG in which this type of digital twin is being used?
Viktor Gaponenko: Yes, we have been implementing such projects for several years now. We recently completed a particularly exciting digital twin project. We virtually modeled the entire process of a high-bay warehouse with 10,000 pallet spaces and seven cranes down to the smallest detail. In addition to fieldbus emulation, we also simulated drive systems, safety modules, RFID devices and other industrial behaviors in this project. Together with 12 virtual PLCs and the connected Warehouse Control System (WCS), this complete digital twin enabled smooth virtual commissioning. The project was carried out by various teams working closely together across Europe.
Let’s take a look into the future. Where is technical development heading?
Michael Kasseckert: We are at the beginning of a new era that is characterized by generative AI. Rather conservative approaches that have characterized our industry for many years are now being broken up. We now need to follow this path in order to remain competitive.
The development of digital twin technology faces a fundamental challenge: the digital twin products currently in use lead to strong vendor lock-in and a concentration on isolated solutions with high license costs, which in the worst case limits the development of the technology. We want to resolve this by using easily accessible and well-known technologies.
Are there any concrete plans for how SpiraTec intends to proceed?
Viktor Gaponenko: It is important to us to play an active role in shaping the technological future. We are currently in the planning phase of an open source platform for open commissioning. The aim is to use and build on the existing open source community and work together on new provider-independent digital twin solutions. As in many cases, swarm intelligence can also be the key here. An open platform by engineers for engineers is certainly a good way to speed up development.
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