The Roadmap for Successful
Simulation and Emulation Projects
Simulation vs. Emulation
Simulation:
• A tool to investigate parameters of a system.
• Used primarily to test variables.
• High speeds / long runs. Production Line
• Multiple scenarios.
Simulation vs. Emulation
Emulation:
• A tool to replicate the inputs/outputs of a system.
• Used primarily to debug code.
Processor Production Line
Outputs
Inputs
Simulation vs. Emulation
Simulation: Emulation:
• Virtual System • Virtual System
• Internal Logic • External Logic
• No Communications • Communications Required
• Used at Design Stage • Used at Execution Phase
• High-Speed • Real-Time
• Answer Specific Questions • Debug PLC Code
(metrics)
The Value of Emulation
• The controls engineer can debug code by testing it on a virtual
production line rather than the real thing.
– Line controls debug & validation prior to start-up (95% complete).
– HMI debug & validation prior to start-up.
– Early design review & scenario testing.
– Vertical start-up!
• Typical Emulation Uses:
– Writing code for new production lines.
– Updating code for existing production lines.
– Training operators offline.
The Value of Emulation
• Emulation increases the lifecycle of
a model: Design
– Feasibility Study: Simulation
– Design Phase: Simulation
– Execution: Emulation
Execution
– Start-Up: Emulation
– Training: Emulation
– Line Improvements: Emulation
Operations /
• The savings during Start-up alone Maintenance
usually offset the model’s cost.
Value of Emulation
Concept
Definition
Design
Typical Procurement
Installation
Project Logic Debug
Training
System Debug / Startup
Concept
Definition
Design
Time Saved &
Emulation Procurement
Installation
Money Earned
Project Logic Debug
Training
System Debug / Startup
How to Emulate
Scope Data Equipment Model Logic
Construction Construction
Communication Debug
Definition Collection Review
How to Emulate
Scope Data Equipment Model Logic
Construction Construction
Communication Debug
Definition Collection Review
Implementation
How to Emulate
Scope Data Equipment Model Logic
Construction Construction
Communication Debug
Definition Collection Review
Implementation
How to Emulate
Scope Data Equipment Model Logic
Construction Construction
Communication Debug
Definition Collection Review
Implementation
• RSLogix 5000
• RSLogix Emulate 5000
• RSLinx Gateway
• FactoryTalk
Case Study : # 1 New System
Programming a Reject Station:
– Reject station was very near the filler.
– Upon rejection, the filler stopped.
– How to keep the filler running?
Case Study #1: New System
Programming a Reject Station:
– Controls Engineer used an emulation model to test
different settings.
– It was found that a solution did not exist for the
current hardware configuration.
– The equipment had been ordered, but not yet
installed on site.
– THERE WAS STILL TIME!
Case Study #1: New System
The Solution:
– The only way to keep the filler running was to modify
the layout: move the reject station.
– Imagine discovering this during start-up.
Case Study #2: New System
Design of the labeler area:
– 6 VFD motors
– 6 photo-eyes
– One bottle stop on the labeler
Case Study #2: New System
Q: What needs to be controlled?
A: Bottle Pressure Before the arrow, bottles need
space between them to alleviate
pressure.
After the arrow, bottles must be
back-to-back for machine stability.
Case Study #2: New System
• A prior simulation revealed required system
behavior, but how do you get there?
• Debugging the system with emulation:
– Is the machine’s status stable?
– Are the VFD motors’ speeds stable?
– Are the bottles backed up to the critical control
point?
– Are the system controls consistent with our design
standards?
Case Study #2: New System
Stabilizing The Controls:
speed
The system is
working when we
see this
time
Case Study #3: Existing System
Photo Eyes
Bottle
Stop
Motor
Case Study #3: Existing System
• The Problem:
– Operators said the labelers were cycling off and on.
– Labeler B didn’t work as well as Labeler A.
– This problem caused line downtime.
– Due to poor performance, the facility couldn’t
afford to take the line down in search of answers.
• The Approach:
– Model the system and gather data virtually.
– Debug code in the office, rather than on the line.
Case Study #3: Existing System
• The model produces the following flow rates:
Labeler A
1000
800
( bpm )
600
400
200
0
Labeler B
1000
800
( bpm )
600
6
400
200
0
0 10 20 30
( minutes )
• Labeler B is definitely unstable.
Case Study #3: Existing System
• Our controls engineer recreates the line
conditions that cause the problem.
• They now watch to see what is specifically
causing the problem.
• As they modify the PLC code the model
reflects the changes immediately.
• It turns out to be a photo-eye that controls
the labelers’ speed.
Case Study #3: Existing System
• In this case, four rungs of ladder logic needed
to be changed to stabilize the labeler area.
• This resulted in a 10% rise in efficiency.
Case Study #3: Existing System
• The updated system’s flow rate:
Labeler A
1000
800
( bpm )
600
400
200
0
Labeler B
1000
800
( bpm )
600
400
200
0
0 10 20 30
( minutes )
• After the changes were made to the actual line PLC,
the client immediately realized the productivity gain.