Digital Twin for Machine Safety

Schmersal showcasing 4D model for safety components for the first time at SPS in Nuremberg.

submitted by Schmersal

Wuppertal, Germany-headquartered Schmersal is set to showcase a 4D model of its safety components for the first time at the Smart Production Solutions (SPS) 2024 tradeshow in Nuremberg, Germany, on November 12-14. The model is a digital twin of Schmersal’s AZM40 solenoid interlock and DHS door handle system. In addition to the three-dimensional (3D) representation, the virtual image simulates all properties and functions of the physical devices as a fourth dimension (4D). If, for instance, a guard door is unlocked using the real button on the door handle, the LEDs on the digital twin light up in the same way as on the physical counterpart. This makes Schmersal one of the very first companies to develop a digital twin for safety components.

The Schmersal Safety 4D model simulates not only individual components, but also complete process and control sequences using virtual mapping of signal flows. The benefit: In addition to early fault detection and optimization, the 4D model will also aid with virtual machine commissioning in the future — even before the real machine has been mechanically assembled. This will help save costs and reduce unnecessary development loops. 

In addition to early fault detection and optimization, the 4D model will also aid with virtual machine commissioning in the future.

In the future, it should also be possible to monitor the components as a prerequisite for predictive maintenance. Volker Heinzer, strategic product manager for programmable electronic systems and Industry 4.0/IIoT at the Schmersal Group, said:

“Our plan is to offer the Schmersal Safety 4D model to customers as a future service, e.g., via our website or online store for 4D models — TwinStore — a platform on which component and system suppliers can make their digital twins available. To this end, there will be a range of successive digital ‘model catalogues’ containing the 4D models of Schmersal products.” 

Schmersal is using ISG-virtuos simulation software from ISG Industrielle Steuerungstechnik GmbH for the Safety 4D model. The CPU-intensive simulation model is computed on the ISG real-time target. This powerful, yet ultra-compact, industrial PC enables loss-free, real-time physics simulation. It represents the complete machine or system from the point of view of the control system, is mobile thanks to its compact dimensions and can also be installed inside the switch cabinet.