The Satellite Review Magazine The Satellite Review Magazine Vol 2 | Page 16

THE 5-STEP SIMULATION APPROACH
TO BETTER INFORMED AUTOMATED
SYSTEM CHOICES
By Ian McGregor, Director, Emulate 3D Ltd.
Dynamic simulation is a powerful tool
for understanding the operation of a
proposed automation system before
it exists, and it is important to understand how and when to use it correctly
in order to get the most returns from
it. Different levels of simulation are
appropriate at various stages of any
automation project, assisting the decision-making process and verifying the
correct operation of the resulting system
at each step.
These steps are as follows:
1. Dynamic Dimensioning
2. Static Equipment Layout
3. Dynamic Demonstration and Communication
4. Experimental Throughput Analysis
5. Control System Verification and
Commissioning
1. Dynamic Dimensioning
Initial solution development is based
on numerical data, which may be
incomplete or synthesized from similar
existing systems. Although spreadsheets
certainly provide a useful means of initial analysis, a simulation approach adds
the ability to incorporate time-based
elements such as the dynamic scheduling of resources, for example operators
or fork lift trucks, making the model
more accurate and representative. This
initial simulation step efficiently moves
towards a robust solution via informed
decisions, but it cannot be considered a
complete view of the system as it lacks
the physical information of the layout,
which provides further constraints
which must be included and understood.
2. Static Equipment Layout
The initial numerical analysis results

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The Satellite Review

in a set of parameters which define the
physical elements required in the system, such as queue sizes, storage areas,
number of work cells, etc. The layout of
this equipment introduces dynamic flow
constraints which impact performance,
as well as static requirements which impact capital equipment choices as well as
operating costs.
3. Dynamic Demonstration
and Communication
Bringing the system to life by superimposing the dynamic order flow onto the
layout is an important step in bringing
understanding and reassurance to the
project stakeholders. There is no better
way to ensure the system operation has
been understood than by demonstrating key parts of it using an animated
demonstration. The most recent developments in immersive virtual reality
allow viewers to easily move around
within the proposed system and to inspect various parts at their leisure.
4. Experimental Throughput
Analysis
Once an automation project has been
given the green light, the simulation
model resulting from stage one is often
revisited with more accurate data sets
and combined with the physical constraints of the layout and equipment
choices. Although some further refinement of the chosen hardware may take
place at this stage, the main motivation
behind this detailed throughput simulation is to fully develop the operational logic and to understand the
resulting system response under various
load conditions. Studying the control
sequencing for a variety of possible
situations and using the simulation to
develop a robust solution early in the

project development cycle pays dividends. These become obvious as the
systems goes through factory acceptance testing and into full production.
Detailed simulation can also form the
basis for the creation of robust operational procedures for product changes,
maintenance schedules, breakdowns,
start up, and so on.
5. Control System Verification
and Commissioning
Testing the control system against an
accurate model of the real system saves
time on site and reduces costs considerably. Virtual commissioning is an
effective and efficient means of carrying
out the logical verification of the control
system off site, and off the project’s critical path. Use of a credible model to do
this gives controls engineers the ability
to create easily repeatable sequences
of loads in a way that is often difficult
in the real world. As virtual commissioning can begin much earlier in the
project than real commissioning, a
more complete study can be made of the
system, resulting in a more thoroughly
tested system. Operators can be trained
using virtual commissioning systems,
as the HMIs and SCADA systems they
will be working with are an integral part
of the emulation, and will operate the
model in the same way as the real plant.
The various applications of simulation
as described here are all designed to
produce better real solutions at a lower
cost, with a high level of operational
understanding and decision traceability. Simulation allows stakeholders to
maintain a shared definition of the
solution as it progresses from initial
concept to operational system, passing
through structured improvement and
robust testing as it does so. Simulation
is neither an optional extra nor a “nice
to have” way of visualizing a solution; it
has truly earned its place as an essential
engineering tool in the armory of all
industrial engineers.

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