Identifying problems before they occur

Virtually presenting products and processes before they are implemented in reality: What may sound like science fiction is the core of the so-called “digital twin”. KEB Automation has dedicated itself to precisely this concept in an innovation project. Improved commissioning and maintenance options for energy optimisation were the goal.

Focus on commissioning and predictive maintenance 

Two use cases were the focus of KEB's research work within the project. 

1. Virtual commissioning: The aim of this use case was to detect and eliminate errors in the automation system using simulations as well as in the development and validation of the system's PLC code. Real or virtual PLCs are connected to the simulation models of the machine or system for this purpose, which simulatively map the behaviour of the planned machine or system. Especially when it comes to the correct mapping of energy flows, simulation models with a high level of detail are necessary. Therefore, methods were developed to create simulation models of KEB frequency inverters on the basis of the original firmware and to integrate them comprehensively into various simulation tools.
    
2. Predictive maintenance: Increasing the availability of systems is the core of this use case. This is to be achieved by continuously evaluating condition data by using the digital twin. A concept was developed to identify critical subcomponents and their causes of failure. Sensor and state variables of the KEB units, which could serve as indicators for deviations or input variables for lifetime models, were determined. A communication infrastructure was also defined to transport data from KEB components to a cloud-based platform such as KEB NOA. There, they are monitored with lifetime models or algorithms that detect irregularities.