The future of automated machines development

Explore the Virtual Commissioning demos created with iPhysics: an overview of the applications of this innovative solution for the design and simulation of machines, lines and production plants

Virtual Commissioning DEMO

How to accelerate the configuration of a robotic end-of-line thanks to the digital twin

With iPhysics, it is possible to establish a TCP/IP connection with ABB Robot Studio software. Therefore, a software-in-the-loop (SIL) approach is used, allowing the direct connection of the logic developed in ABB Robot Studio with that of the planned palletizing line. Signals from the line sensors can then be exchanged with ABB Robot Studio to control and verify the Robot's behavior.
This way, system integrators can validate the overall project, using ABB code that will later be put into production.

iPhysics enables the step-by-step integration and simulation of all mechanical and automation elements, including real or emulated PLCs, allowing complex projects to start even before the hardware is delivered and significantly reducing setup times and mechanical and automation design errors.

Virtual Commissioning DEMO

How to model a product sorting line, based on radio-frequency-identification (RFID) technology

In iPhysics, it is possible to work in CAD-coupled mode, allowing continuous collaboration between automation designers and mechanical designers. Thanks to the plugin developed by Machineering, it is possible to make changes to components in Solidworks and immediately synchronize them with the simulation environment while preserving the properties of the virtual commissioning model. Additionally, you can define the behavior of conveyor belts, specifying their direction, motion law, and friction coefficient.
To complete the sorting line, RFID readers have been implemented to recognize incoming products based on associated tags.

Finally, it is possible to gather statistical information about the behavior of dynamic elements. In this example, the impact coordinates of the products were exported to .csv files, plotted, and subsequently analyzed in Python.

Virtual Commissioning DEMO

How to create digital twins of manufacturing plants that include operators, machinery, AGVs and robots

In iPhysics, it is possible to create digital twins of production facilities that include operators, machinery, AGVs (Automated Guided Vehicle), and robots. This is the case with SMACT Rovereto, with which we are working in sync to simulate existing and future solutions to be integrated into the physical shop floor.

In addition to visualizing and designing complex and flexible production flows, iPhysics features an HMI interface that allows the user to interact with elements of the digital twin to analyze and validate the behavior and output of complex machinery, such as the illustrated laser cutting, AGV movement, and robot manipulation.

Equally important is the ability to derive process data and statistics from the simulation for logistic optimization.

Virtual Commissioning DEMO

How to design complex logistics systems

In iPhysics, it is possible to design complex logistics systems. It is easy to quickly model a vertical warehouse served by a series of conveyor belts.

In the example presented, these conveyor belts are controlled based on the position of the containers, detected by infrared sensors distributed along the path. Additionally, it is possible to model motorized rollers, specifying their direction vectors. These are used to direct the containers before they are loaded onto the vertical lift system, which positions them in predetermined slots. Each slot is equipped with infrared sensors to monitor the real-time capacity of the vertical warehouse.
Each container is modeled as a dynamic element, and as you can see, iPhysics is capable of handling a significant quantity of them without limiting the simulation speed.

Virtual Commissioning DEMO

Production line layout development

In iPhysics, it is possible to create digitaltwins of production lines by integrating all the elements: automated stations, manual workstations, employees, and robots.

In the presented example, products from the upstream flow are grouped and stored by the first robot in containers from a forming line (cartoning). Subsequently, each box is weighed, and if it is non-compliant, it is checked and possibly rejected by the operator. Finally, the boxes are sealed and palletized by the end of line.

The simulation of operators in iPhysics allows for the planning of their movements, actions, and tasks within the shop-floor. This enables the estimation of the timing of manual operations in the production process and the verification of the interaction between operators and automated systems.

Virtual Commissioning DEMO

Robotic feeder

Thanks to iPhysics, it's possible to simulate the behavior and automation sequences of robotic feeder.

The created model utilizes source that randomizes the positions at which the components are introduced. This allows for simulating the manual loading of products onto the conveyor belt. The generated elements are transferred to an elevator belt, which then bring them to a vibrating feeder. The feeder uses the vibration driver available in iPhysics, allowing for precise simulation of the effects of parameters of this type of actuator, such as vibration frequency and amplitude.
Once the products are distributed on the main conveyor belt, a vision system communicates the positions to the delta robot, which performs the pick-and-place operation to arrange them as required.

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