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Online simulation at machine level: a systematic review

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Abstract

The importance of simulation at the machine level in industrial environments is steadily increasing especially in the design and commissioning phase. Using models during the operation phase together with the real machine or plant is referred to as online simulation. Online simulation is used for system monitoring, predictive analyses, decision support, or online optimization and therefore has various advantages and a wide field of applications. This paper aims to characterize online simulation at the machine level in industrial automation focusing on key technologies and common applications. Therefore, a set of 65 relevant publications, which are focusing on this subject, is found by database search, expert consultation, and snowballing. As key technological aspects, the used model types, interfaces, and platforms, and the aspects of initialization and synchronization are further investigated. The results are interpreted and limitations, knowledge gaps, and future prospects are discussed. The potential of online simulation at the machine level especially arises due to the increasing availability of component and machine models from the design and commissioning phase, which can be reused for online simulation. The remaining challenges are identified concerning implementation, simulation platforms, model maintenance, and especially in the field of synchronization.

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Funding

The work presented in this paper has been partly funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK) under the project 13IK001ZF “Software-Defined Manufacturing for the automotive and supplying industry https://www.sdm4fzi.de/”.

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Authors and Affiliations

  1. Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW), University of Stuttgart, Seidenstraße 36, 70174, Stuttgart, Germany

    Darius Deubert & Lars Klingel

  2. Bosch Rexroth AG, Bgm.-Dr.-Nebel-Straße 2, 97816, Lohr am Main, Germany

    Darius Deubert & Andreas Selig

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  1. Darius Deubert
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  2. Lars Klingel
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  3. Andreas Selig
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All authors contributed to the study conception and design. Material preparation and data collection were performed by Darius Deubert and Lars Klingel. The first draft of the manuscript was written by Darius Deubert and was reviewed by all authors. All authors read and approved the final manuscript.

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Correspondence to Darius Deubert.

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Deubert, D., Klingel, L. & Selig, A. Online simulation at machine level: a systematic review. Int J Adv Manuf Technol 131, 977–998 (2024). https://doi.org/10.1007/s00170-024-13065-1

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