Virtual testing is an important step in the manufacturing process of robotized palletizing
and bulk packaging lines. They enable us to identify potential problems, as well as optimize the applied solutions prior to their physical implementation. Virtual testing involves simulating different scenarios and approaches based on digital models.
DEVICE DESIGN TESTING
The first step is to test device models for their reliability and durability. Wikpol engineers examine the state of internal stresses and deformations of individual machine parts under the conditions of mapping their actual mechanical loads.
The strength calculations for the key elements of the machines minimize the risk of damage during actual operation.
Testing of reduced stresses according to the von Mises method – frame
SIMULATION OF LINE OPERATION IN A DIGITAL ENVIRONMENT
Line testing in a digital environment is performed on the basis of a virtual version of the real line. It involves designing and checking various production scenarios.
By testing different variants of the processes that take place on the production line, such as:
we can correctly assess which solution will be effective from the customer’s point of view.
During the simulation, various aspects of the processes can be verified and optimized, e.g.:
The basic simulation tools we employ at Wikpol are:
1. Software to simulate the operation of robots
It is used to model the work of the robot and its control for quick, trouble-free configuration. It enables simple planning of work paths with the use of animation (visualization of ranges and precise mapping of work cycles). Consequently, it allows us to select the optimal unit for the respective application.
Robot simulations include the following parameters:
2. Line operation testing software
Modelling of the operation of robotized palletizing and packaging lines can be carried out at different levels. It is helpful in designing and verifying all elements that have an actual impact on the performance and optimal operation of the system, such as:
In the case of control systems, one of the aspects of virtual testing is the verification of safety. It consists in simulating various hazard scenarios, such as collisions or malfunctions of devices, and checking whether the system reacts correctly and secures a safe working environment. In order to investigate whether the program operates according to the assumed control algorithm and whether it is resistant to interference, PLC programmers trigger emergency situations in order to learn how to react to adverse events in the future.
Line simulation allows to identify potential errors and issues, such as delays in the course of production processes or machine failures, before the actual production line is constructed. The information obtained about the actual operation of the line is used to optimize its design.
BENEFITS OF LINE SIMULATION:
Cost savings
Time saving
Improvement of product quality
Optimization of operation
Virtual tests of devices and production lines are crucial, as they allow us to ensure their effective, safe and optimal operation.
