Virtual Commissioning with FMU Co-Simulation
Optimizing Engineering Process for Water Management Solutions company
Client Spotlight
Our client, a growing automation services company with operations in Germany and India, partnered with a renowned Global Water Management organization based in Europe. Known for its expertise in Robotics, Simulation, and Virtual Commissioning, the client was tasked with delivering an advanced Virtual Commissioning (VC) solution tailored to the specific operational needs of water management systems.For this project, the challenge was to create a reliable VC system capable of simulating, testing, and optimizing plant operations in a controlled virtual environment.
Challenges
Our client was tasked with developing a Virtual Commissioning (VC) solution for a prominent European Water Management company. However, several critical challenges hindered the development process:
Lack of Direct Connectivity
The Simulation Software and Virtual Commissioning Software lacked direct integration capabilities. This absence of connectivity made it difficult to develop a comprehensive VC solution, limiting the organization's ability to streamline and optimize its engineering processes.
No API or Interface Manual
The Simulation Software did not provide an API or any detailed interface documentation. This limitation created significant challenges for custom solution development, as the lack of technical guidelines left the development team without a clear path for system integration.
Dependency on FMU 2.0 Protocols
The Simulation Software could only interface with Functional Mock-up Unit (FMU) 2.0 programs, an industry-standard protocol for exchanging simulation models. Developing the solution required specialized knowledge in the implementation and handling of FMU 2.0 guidelines.
Complexity of Cross-Platform Integration
The challenge was not just about connecting two systems, but about ensuring the seamless exchange of data between Simulation and VC systems. This required a deep understanding of both platforms to ensure real-time synchronization and performance accuracy across multiple engineering disciplines.
Our Solution
Journey To Success
The development of this Virtual Commissioning solution spanned approximately four months and followed a phased approach. The project began with a detailed analysis of FMU 2.0 standards and Virtual Commissioning API manuals to map out the integration requirements.
Given the unique challenges, the team maintained a flexible approach, adjusting the solution design as new insights emerged during the testing phases. Early prototyping played a crucial role in validating key technical aspects before the full-scale development.
Throughout the project, close collaboration with cross-functional teams, including simulation and control experts, ensured a well-rounded solution. The result was a robust middleware that successfully bridged the gap between the Simulation and Virtual Commissioning systems, allowing the client to perform real-time virtual testing and reduce risks associated with live deployment.
Technology in Action
- .Net
- C
- C#
Impact and Results
The newly developed middleware solution brought significant advantages:
Improved Integration
Seamless co-simulation between the Simulation and Virtual Commissioning platforms allowed for more comprehensive and precise virtual commissioning, enhancing the overall engineering workflow.
Increased Efficiency
Engineers could now design, test, and validate their systems in a cohesive environment, minimizing errors and speeding up the development and deployment phases.
Scalability & Flexibility
The solution’s adherence to FMU 2.0 standards ensured compatibility across different systems, enabling easy adaptation for future projects and updates.
Cost-Effective
Early identification of errors and simulation-based commissioning reduced the need for extensive physical testing, lowering project costs and risks.