Emulation

What We Do

Emulation for Logic Validation

The Design Systems, Inc. emulation process establishes a virtual environment for a material handling system with full functionality, feedback, and a 3D graphical view of the complete system. It also creates representations of control panels and allows the common field faults to be applied to the PLC logic. This environment allows an entire material handling system to be analyzed in an office setting without impacting production. We also have the ability to easily stage test scenarios and run the system at full volume to verify capabilities.

Emulation provides a variety of checking mechanisms to allow the customer and the project partners to verify that the deliverables are in compliance with the scope of work, proper standards, and control methods. Additionally, It also affords the ability to interconnect and effectively test associated control and diagnostic hardware prior to plant installation, further reducing start-up time and providing additional cost savings.

Review PLC program and identify I/O required to run the Emulation model
Identify
Develop detailed model, including required field devices (proxes, photoeyes, etc.) per design layout and I/O listing
Develop
Set up the OPC server communication which serves as the interface between the PLC and the Emulation model
Communicate
Test / Run the Emulation model
Run
Verify PLC logic, HMI’s, and MES (alarms, graphics, part data, etc.)
Verify
How We Do It
The Design Systems, Inc. emulation process establishes a virtual environment for a material handling system with full functionality, feedback, and a 3D graphical view of the complete system. It also creates representations of control panels and allows the common field faults to be applied to the PLC logic. This environment allows an entire material handling system to be analyzed in an office setting without impacting production. We also have the ability to easily stage test scenarios and run the system at full volume to verify capabilities.
Why We Do It
  • Bridge to Simulation
    • Emulation provides a bridge to simulation

  • Reduces Development
    • Reduces control system development and debug time prior to installation so development time is easier to manage.

  • Lab Environment
    • Provides system testing in a lab environment without the need for trades.

  • Off-Line Tool
    • For Maintenance personnel, provides an off-line tool for training and testing of fault responses.

  • Reduced Costs
    • Reduced commissioning costs due to reduced systems validation time on the plant floor.

  • Testing
    • Allows testing of complex product blends and production scenarios for Production personnel.

  • Risk Mitigation
    • Start-up and Schedule Risk Mitigation.

Benefits
  • Minimal debug and start-up times
  • Logic debug before construction
  • Test complex routing requirements
  • Operator and maintenance training
  • Start-up schedule and production risk mitigation
  • Substantial start-up cost savings

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