The Challenge

From concept to implementation, the resources, funding, and time required to launch a manufacturing facility is proving to be a constraint on a company’s ability to compete effectively.

Result

Pilot Systems excels at bringing together a network of problem solvers to develop solutions for our customers. Pilot Systems worked with subject matter experts and partners in developing a roadmap, digital twin concept and prototype for a smart manufacturing application. This included performing virtual commissioning which integrated both mechanical and electrical environments.

The complexity of manufacturing systems is rapidly increasing across many industries.  Digital Twins, System Engineering, Data analytics, Controls Systems, Sensor fusion and Artificial Intelligence are all key enablers to helping manufacturing companies manage this complexity and develop cost effective products.   The enablement of a Digital Twin is a key element in a company’s ability to survive and develop innovative and new products according to industry 4.0 and IIOT standards.

Digital Twins are virtual representations of a physical object, system or process which predicts the physical object’s performance characteristics.  Once validated and optimized, the virtual representation is deployed physically to become a functioning facility.

The Digital Twin concept has great potential to revolutionize manufacturing.

The pairing of the virtual information with physical presence allows for the analysis of data to head off problems before the cost of a physical machine or building is incurred.  It pre-verifies and validates the manufacturing process, which results in a shorter ramp up & launch time, reduces system cost, process efficiencies, minimizes downtime, etc. and improves overall quality and optimization of the final product or process.

Digital Twins also allow you to generate ‘what if’ scenarios to maximize your capital equipment and human (operator) utilization, plus, produce cost effective measures to improve your overall margin.

Digital Twins accurately represent the physical system's layout and motions. Simulation activities are performed which streamline controls engineering and develops logic for testing and debug before being deployed on the physical counterpart. It also allows control engineers to simulate the connection to the PLC by integrating mechanical & electrical logic thru virtual commissioning. Virtual Commissioning simulates mechanical behavior early in the mechanical engineering and manufacturing process which is used to validate controls logic prior to production build.

Areas of Expertise

Systems Engineering, Controls Systems, Industry 4.0, Smart Manufacturing, Data Analytics, AI

For more information, please contact us.