A clear insight in 3D
igm relies on live visualization with atvise® and digifai.
What was once science fiction is now reality: igm Robotersysteme utilizes 3D simulations to control welding systems more transparently and efficiently. With digifai and the atvise® platform from Bachmann, a solution was created that links live data with realistic 3D models. The result: shorter commissioning times, fewer errors, and intuitive access to all machine data.
How it started: a technological alliance
For several years, atvise® has been igm’s SCADA system of choice for visualization and machine data acquisition. igm’s own HMI system, “igm Control Panel” (iCP), is based entirely on atvise®, and performs tasks including visualization, control, program selection and documentation. Machine data is stored in an SQL database and used for analyses: either on site at the installation, or from the office with use of a web browser.
Virtual commissioning
As for the virtual commissioning of a new welding plant, igm tested the use of a 3D simulation. This led to cooperation with digifai, which uses its twin simulation software to create advanced 3D simulations and digital twins for automation systems.
The web-based architecture of twin and atvise® enabled the two systems to be integrated seamlessly. twin not only permits realistic representation of complex systems in 3D, but also links them to live data and interactive information on components, states and processes. The aim was to extend the existing visualization with addition of an intuitive 3D live view – for greater transparency, efficient commissioning and optimized control of installations.
Live 3D simulation on the machine
igm’s systems are often physically large, contorted and difficult to view. Integrated 3D visualization was intended to address several challenges:
- Visibility of robot movements, particularly at welding points that are difficult to view
- Easy identification of components and replacement parts, including direct linking to documentation and ordering information
- Web-based access to machine information, including remotely, and without special software
“When the robot enters the component, you need either a camera or – as in our case – 3D visualization. You can move to any point you choose, and zoom in,” says Patrick Palitsch. “But we’ve also integrated parts list information and replacement parts into the 3D representation. The operator only has to click on the component to view the desired documentation.”
The benefits are particularly evident during maintenance and repair: information can be accessed immediately, and handling is significantly more efficient.
Fast, open, standardized
The project was completed within four weeks. This was possible thanks to the open, web-based structure of the two systems. digifai and igm's solutions were already in use in productive applications. “All we did was to marry the two systems,” as igm puts it. The result: the system’s operation is accompanied by a live visualization, and clicking on a component calls up additional information on it, including relevant images and documents.
Virtual commissioning for predictive planning
Another highlight of the project is advance virtual commissioning. digifai’s simulation enabled potential bottlenecks and conflicts to be identified and eliminated while the project was still at the planning stage. Interfacing the 3D drawing to the PLC simulation enables the commissioning process to be played through realistically in advance.
The advantages are obvious: shorter commissioning times, enhanced safety and a substantial reduction in unanticipated errors in actual operation.
Customer-oriented further development
The project is not a completed job, but forms the basis for ongoing development. Work towards a specific development goal is already in progress: “Besides visualizing robots and workpieces in real time, we’re also working on displaying the weld seam in 3D – in other words, visualizing the exact progress of the welding process,” says the igm project manager.
Efficient, open, fit for the future
The project at igm demonstrates impressively how the combination of atvise® and 3D technology delivers modern automation solutions that are not merely technically impressive, but also suitable for implementation in real-case scenarios. The benefits for commissioning, maintenance and operational monitoring are self-evident.
“Cooperation with our two partners went without a hitch. When a problem crops up, we can always resolve it quickly,” is how Patrick Palitsch sums up the working relationship.
Looking to the future, one thing is certain: for igm, 3D visualization is not just an innovative tool, but an essential part of ongoing product development and customer retention.
Customer Profile
igm Robotersysteme AG is among the leading suppliers of automated technology for the welding of large, complex components. The company’s solutions for welding tasks range from large gantry systems up to 100 metres in length to custom compact cells. They also involve the use of igm manipulators, capable of handling components weighing up to 50 tons and positioning them for the robot. With over 4,000 systems installed worldwide, igm offers custom solutions for industries including earth-moving machinery, railway and crane construction, forklift truck manufacture and mining.
digifai develops practical software solutions for industrial automation. With products such as twin, the leading all-round simulation software for digital twins, and control, for IoT-based monitoring, digifai delivers virtual commissioning, efficient process monitoring and the digitalization of industrial processes. The brand is part of Eberle Automatische Systeme GmbH & Co KG, an independent systems manufacturer based in Dornbirn, Austria. The company combines many years of automation expertise with the development of innovative software for Industry 4.0 applications.