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Middleware for Virtual Commissioning

Middleware for Robot, PLC, Simulation and Virtual Commissioning System Integration

Client Spotlight

Our client is a leading Japanese robot manufacturer with a robust global presence. Renowned for its advanced robotics technology, the client not only manufactures cutting-edge robots but also provides comprehensive services in building and integrating plants and cells for customers worldwide. Their expertise spans across various industries, including automotive, electronics, and manufacturing, making them a key player in the global robotics market.

This case study highlights how we partnered with the client to develop a sophisticated middleware system that connects robots, PLCs, Virtual Commissioning, and simulation software, enhancing their ability to deliver seamless and integrated solutions to their diverse clientele.

  • Industry

    Robotics

  • Location

    Germany and India

  • Duration

    6 months

Challenges

Lack of Integration Interfaces

The existing robotic software system lacked integration interfaces with Virtual Commissioning (VC) software, obstructing the exchange of robot axis and PLC signal data. This gap hindered the development of an effective Virtual Commissioning solution.

Complex System Interaction

Developing a successful Virtual Commissioning solution necessitates interaction between robotic software, VC, PLC, and simulation systems. The absence of seamless integration between these components posed significant challenges.

Strategic Necessity and Knowledge Gaps

Adoption of Virtual Commissioning was crucial for the client as it aligned with their digital strategy and aimed to reduce overall plant development costs. While the client was proficient with their proprietary robotic software API, they lacked expertise in other software systems necessary for building the solution in-house.

Our Solution

  • In-Depth Analysis and Requirement Identification

    Our team thoroughly reviewed both the Robotic Software API manual and the Virtual Commissioning (VC) Software manual. This comprehensive study allowed us to pinpoint the specific areas requiring integration and to align our solution with the client's requirements.

  • Development of Integration Solution

    We engineered a robust middleware solution that established a direct connection between the Robotic Software and the Virtual Commissioning software. This integration facilitated smooth data exchange, bridging the gap between the two systems.

  • Accurate Data Mapping

    The solution ensured precise mapping of Robotic Signal I/O data to the Virtual Commissioning data format. This accurate data translation was crucial for maintaining the integrity of data exchanged between the robotic and VC systems.

  • High-Speed Data Handling

    Given that robot axis data changes occurred at intervals of less than 50 milliseconds, our system was rigorously stress-tested. We ensured that no data was lost and that every change in robot axis position was captured and correctly exchanged with other software systems, even under high-speed conditions.

  • Enhanced System Performance

    The integration solution improved overall system performance by enabling real-time synchronization between the robotic software and VC systems. This enhancement allowed for more effective Virtual Commissioning and simulation processes.

  • Future-Proofing and Scalability

    The solution was designed with scalability in mind, allowing it to accommodate future expansions and modifications. This forward-thinking approach ensures that the integration remains effective as the client’s needs evolve.

Journey To Success

From Concept to Comprehensive Integration

Requirement Analysis

The project commenced with a detailed planning phase where the Core Engineering team focused on understanding the client’s requirements. This included an in-depth study of the technical API manuals for both the Robotic Software and Virtual Commissioning (VC) software, which was crucial for developing an effective integration solution.

Development of Individual Robot Cells

To facilitate a seamless integration, the team developed distinct robot cells within each software system. These cells were tailored to represent different phases of the project and were essential for ensuring that each component functioned correctly.

Unit Testing: Individual robot cells were tested in isolation to validate their functionality and integration readiness.

Performance Testing: The cells were then subjected to performance testing to ensure they could handle high-speed data exchange and maintain system stability under load.

User Acceptance Testing (UAT): Finally, the cells underwent UAT to confirm that the integrated solution met the client's expectations and requirements.

Solution Development and Integration

The solution development involved connecting these robot cells across the different software systems. The team implemented the standard phases of the Software Development Lifecycle (SDLC), including design, development, testing, and deployment, to ensure a structured and thorough approach.

Testing and Validation

A dedicated phase was allocated for extensive testing, which included stress testing and validation to ensure that the integration performed as expected and met the high-speed data handling requirements.

Successful Deployment

The project concluded with the successful deployment of the integrated middleware solution. The careful planning, phased testing, and adherence to SDLC processes ensured that the final solution was robust, reliable, and aligned with the client’s operational needs.

Technology in Action

  • .NET icon .Net
  • C#

Impact & Results

The newly developed middleware solution offers several key advantages:

Virtual and Real-World Testing

Users can now test virtual robots in conjunction with real or virtual PLCs using the Virtual Commissioning software. This capability allows for comprehensive simulation and validation of robot interactions within various operational scenarios.

Bidirectional I/O Communication

The system facilitates bidirectional communication of I/O signals between the PLC and the robot. This integration ensures that data flows seamlessly in both directions, enhancing real-time control and monitoring capabilities.

Comprehensive Peripheral Communication

The middleware supports bidirectional I/O communication between the robot and its internal and external peripherals. This feature ensures that all connected devices and components can interact efficiently, improving overall system coherence and functionality.

Efficient Axis Value Communication

The solution provides unidirectional communication of robot axis values, ensuring precise and accurate data transfer regarding the robot's positioning and movements. This feature supports accurate simulations and effective control within the Virtual Commissioning environment.

Lessons Learned

Early Design of UAT Cells

It is crucial to agree upon and design the cells that will be used during User Acceptance Testing (UAT) early in the project. Early alignment on these components helps prevent delays and ensures a smoother testing phase.

Inclusion of Functional Experts

Given the integration of four independent software systems from different engineering disciplines, having functional experts or end users from each software present during UAT is essential. Their involvement helps address issues arising from the limitations of individual systems and ensures a more effective resolution process.

Proactive Integration Management

Identifying and addressing integration challenges between diverse software systems early in the project can prevent significant setbacks during later stages. Proactive management of integration issues helps maintain project timelines and quality.

Continuous Cross-Functional Collaboration

Maintaining continuous communication and collaboration among cross-functional teams is vital. This approach ensures that all components work seamlessly together and allows for prompt resolution of any issues that arise, fostering a more cohesive project execution.

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