Fresh possibilities for digital twins with the integration of tools

The B&R MapleSim Connector makes it efficient for B&R customers to integrate MapleSim, the modelling and simulation tool from Maplesoft. MapleSim creates an accurate, dynamic model of the machine based directly on CAD data. This model can then be used for accurate motor sizing, as well testing and comparing different designs. Additionally, the model can be used within Automation Studio to support the virtual commissioning workflow. This helps avoid the risk of costly design errors by finding them earlier in the commissioning process. 

The B&R MapleSim Connector offers two streamlined export functions for efficient use of digital twins in the development process. First, a model’s simulation data, containing accurate estimates of a motion’s required torque and forces, can be exported in a format directly readable by SERVOSoft. This gives it the information it needs to ‘right-size’ the servo drives, motors and gearboxes. Secondly, the model itself, along with its CAD visualisation, can be exported to Automation Studio for control code testing.

Once in Automation Studio, the model can be simulated and transferred directly to the B&R control hardware. The result is hardware-in-the-loop simulation, where the machine's behaviour is emulated in real time to create a controlled environment where the machine software can be tested safely. In this environment, all control parameters can be manipulated and the temperature behaviour of the drive can be simulated. The behaviour of the digital twin is visualised live in B&R Scene Viewer. 

“Engineers can use Digital Twins to save significant time and cost by finding design and controller code issues well before physical prototypes are built,” said Kurt Zehetleitner, Group Leader, Engineering Software, Simulation and Digital Twin, B&R. “By including the visualisation feedback within Automation Studio, the virtual machine’s dynamic behaviour can be readily observed without having to decipher it from plots and tag values, significantly improving the control code development process.”