GET CLOSER TO YOUR CLIENTS BY KEEPING YOUR DISTANCE
By Ian McGregor , Business Development Manager , Emulate 3D
The New Reality is Virtual
There ’ s a lot to be said in favor of the face to face meeting with prospects and clients to discuss the various aspects of their proposed automation system , and how you ’ ll deliver it to them on time and within budget . At various stages throughout the project you ’ ll be explaining solutions , evaluating and comparing alternatives , designing and testing the control system , and training operators , much of which traditionally takes place on site . But times have changed , and it ’ s no longer as easy , convenient , or safe to do things that way . The good news is that the technology exists to carry out all these tasks effectively and safely without going onsite , in ways which actually accelerate the process too . By using simulation and emulation modeling to create digital representations of proposed automation systems you benefit in two ways . First , by using an open and understandable way to develop better solutions and minimize the risk associated with your choices , and second , by communicating virtually at a distance you eliminate not only the costs but also the delays introduced by face to face meetings .
Collaborative Design at a Distance
Industrial simulation is a tried and tested standard part of any IE ’ s playbook , and the benefits of employing it to analyze and improve product flows , identify and manage bottlenecks , and make good choices between alternative solutions are well established . What ’ s taken a big step forward in this technology over the last few years is the ability to view and interact with models within a Virtual Reality environment . Initially dismissed by some as just another way to view the model , Virtual Reality actually brings a great deal more to the table which adds significant value to the dynamic model . Participants can meet from remote offices within the model – they see each other as avatars with a head , a body , and hands . They can discuss the running model from within it , and they can move around inside it individually or as a group . In addition to this they can interact with the model and loads as it operates – machines can be switched on and off to observe the consequences , product flows can be changed , and the model can be run faster or slower than real time . Any control options built into the model to help demonstrate operation can be triggered from within it , and the results of the changes observed and discussed . Design cycles and costs can be reduced thanks to the immediacy of the approach – whereas a solution review carried out the old way might need to be scheduled a week or so in advance with flights and hotels providing extra constraints , everybody can find twenty minutes this afternoon or tomorrow morning for an online review .
Comprehensive Offsite Controls Testing
Controls Testing differs from simulation in two important ways ; it is used to verify and test the controls once the physical equipment choices have all been made , and controls testing models are connected to the physical controllers running the programs they are testing , so they run in real time . By testing the actual controls offsite and off the project ’ s critical path , users effectively minimize the amount of time they need to spend onsite to carry out the physical commissioning of the system . While much controls testing work is done for the direct benefit of the integrator , system end users can join an emulation model in a virtual environment , just like simulation models , and FAT tests can be carried out which demonstrate the correct operation of the system under a wide range of conditions .
Hands-Off Operator Training
It has always been good practice to train operators of semi-automatic machines and systems away from the real system . Once you have a realistic model , the use of it for training avoids disrupting production , it eliminates the possibility of costly errors and product waste with the
real system , it enables potentially damaging situation recovery to be taught , and it is safer for the operator . The operator can choose the level of help and prompts they wish to have from the model , or the model can track the user ’ s progress and calculate whether to display assistance or not . The use of an interactive model within a Virtual Reality environment adds the visceral feeling of “ being there ”, of realistic system scale , and of course trainers and evaluators can join and participate from remote locations .
Create Great Digital Solutions
Creating dynamic digital twins of your solutions for your clients ’ automation requirements is a cost-effective way to develop effective handling systems and demonstrate them in today ’ s challenging industrial environment . When you need to commission systems and train operators to use them , simulation and virtual controls testing combined with Virtual Reality provide the functionality you need to do a great job for your closest clients while maintaining a respectable distance .
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