Manufacturing companies that aim to increase production rates and to reduce costs need a method to virtually test system behavior. Configurable material handling systems make this particularly challenging, given that a myriad of processes may be involved. These processes include, among others, machining, deburring, measuring, and storage. Virtual commissioning requires the ability to integrate simulation models of the mechanical, electronic, and control algorithms.

Reishauer AG, a producer of high-precision gear grinding machines, addresses this challenge by using Simscape™ to unite CAD designs with mechatronic simulations. Multibody simulation models imported from CAD assemblies are connected to models of PMSM motors, elastic belt drives, and cascaded controllers to simulate the entire system within the Simulink^® environment. To ensure realistic behavior, these models had to be parameterized by input from data sheets. Subsequently, these models had to be compared with actual measurements to verify how closely they would fit reality. This methodology helped to determine which physical effects were critical for achieving the required accuracy.

This presentation covers how an integrated solution makes it possible to perform virtual commissioning, and how to verify designs early in the development process.