The challenge

Three factors play a key role in implementing any industrial plant: adherence to the agreed-upon quality standards, costs, and time. Plants are becoming more and more uniquely designed, while at the same time operators expect increasingly high availability and efficiency right from startup. Modifications and expansions continue well into the operating phase. The consequence is more complex projects, tighter time frames, and more work at cost-intensive times at night or on weekends. Costly additional expenditures can occur in particular when it comes to starting up application software.

Our solution

As a simulation platform, SIMIT provides a comprehensive and scalable range of products and services for the virtual commissioning of application software for automation systems, from signal simulation through simulation of actuators and sensors to the simulation of entire production and manufacturing processes. Simulations provide a way of testing and starting up the software without the actual machine or plant, thereby generating time and cost savings in automation projects and producing higher software quality.

Integrated quality assurance
With SIMIT, the virtual machine or plant is adapted to the automation project as it progresses. A suitable simulation is available in every project phase, through which the correct functioning of the automation system can be ensured. In this way, potential faults are discovered at an early phase in the project and can be eliminated at low cost. Even fault incident scenarios can be played out any number of times without any risk for operator or machine. This raises the quality of the software to a totally new level.

Startup in the office
SIMIT can be connected directly to automation systems and then supply them with process data that is faithful to the original. This means that the automation system can be checked for correct functioning at the office in the same way as when starting up on site. As a consequence, the automation software is delivered to the construction site with the best possible quality, which represents a big step towards “power-on startup.”

Consistent technology and automation
SIMIT makes a virtual machine or system that behaves just like the real thing. It simulates all open- and closed-loop control functions of the machine or system, including processes, control operations, and reactions to faults and operator errors. Technology and automation specialists can therefore verify implementation of the automation functions on a common platform.

Less stressing of machines and systems
The automation software is commissioned without the “real” machine or system, which saves unnecessary stressing of the mechanical components. Even malfunctions that cannot be tested with the actual machine or system because of a high potential risk for people, machine, or environment can be reproduced any number of times with SIMIT. The high coverage of test cases improves quality and increases availability and reliability.

Training
SIMIT can also be used for training of operating personnel. Since malfunction scenarios can be practiced intensively, production outages can be prevented by prompt and effective intervention.
In the ideal case, the training simulation is available even before the actual plant or machine is ready for operation. Trained personnel can then execute a controlled startup of production within a very short time.

Good reasons for SIMIT