Simulation software is developing rapidly and will become an even more important tool for engineering and production in 2025. The focus will be on efficiency, precision and seamless integration into existing processes. Here are the most important trends that will shape the field of virtual commissioning and the digital twin:
1. Cloud-based simulation
The integration of all technologies such as CAD programs, control technology and robotics in a cloud-based platform enables simulations to be carried out flexibly and efficiently. Teams can collaborate globally and benefit from centralized data and a powerful computing infrastructure. This not only simplifies availability and licensing, it also solves the issue of computing power.
However, each company must decide for itself where the cloud server should be located, i.e. whether to work with a third-party provider or host the cloud itself. When selecting simulation software, it is therefore important to consider whether it is cloud-capable and where the cloud is hosted.
If you want to find out more about this topic: The article Cloud-based simulation: revolution in mechanical and plant engineering explains all the important aspects in more detail.
2. AI-supported simulation
Simulation software is increasingly being used as a test environment for artificial intelligence. AI can be trained, tested and optimized in the simulation – a decisive advantage for applications in robotics and control technology, but the use of AI-supported simulation also makes sense for production, e.g. to support image recognition.
3. Real-time simulation
Real-time simulation plays a decisive role in control technology and robotics in particular. This enables precise testing of mechanics and control technology in interaction with the material flow and makes real commissioning much easier.
When choosing simulation software, make sure that no additional tool or plug-in is required for real-time capability in order to reduce the susceptibility to errors.
4. Industrial metaverse
AR technologies and the ability to display simulation models using various glasses take collaboration in engineering to a new level. Teams can work together on projects in an immersive environment and make design decisions directly or jointly optimize machine behaviour or material flow. As part of production planning, virtual systems can already be displayed in the production environment and the material flow can be adapted with the real machines.
Make sure that there are interfaces to VR/AR systems and that further processing of the simulation models is possible. If you are now wondering why you should use simulation software at all when you can use Nvidia, the articles iPhysics in Omniverse – combining the best of both worlds and Simulation Software vs. Visualization Technology: A Critical Comparison provide all the answers you need.
5. Bidirectional CAD integration
A seamless connection between CAD software and simulation models is becoming indispensable. This is the only way to realistically simulate systems and machines. This means that changes in the development or production process can be made directly in the CAD model.
Some providers of simulation software use prefabricated libraries that can be used to create scenes quickly, but often do not provide a precise representation of the real system. Reliable statements about the functionality and performance of future machines are therefore not possible.
You should therefore rely on simulations that are based on the real CAD data of your system. Not only can reliable information on functionality and output quantities be provided, but potential problems in the production environment can also be identified and addressed at an early stage.
6. FMI/FMU
The use of components in the simulation via standards such as FMI/FMU brings considerable advantages in model creation. Simulation models become simpler, more precise and enable targeted testing of individual components in the overall system – a guarantee for higher quality in machine manufacturing.
When choosing the right simulation software, it is helpful to pay attention to an extensive component library. Read the interview with automation expert Dr. Georg Wünsch: What are the benefits of the machineering component model?
7 Automated testing
Thorough testing of the simulation model is crucial in order to avoid potential errors in the subsequent system. Such tests often involve numerous cycles and can therefore be very time-consuming. The process becomes more efficient if the simulation software is able to carry out automated tests independently over a longer period of time, for example overnight. A detailed problem analysis afterwards helps to quickly identify and eliminate weak points. This not only saves time, but also contributes to the quality assurance of real commissioning.
8. Simplified modeling
The effort required to parameterize CAD models in simulation models can be significantly reduced through the reusability of tested modules. The creation of individual libraries enables more efficient development processes, especially for new developments.
9. Energy measurement / Co2 footprint
Simulation software supports sustainable decisions by optimizing resource-saving processes and minimizing energy consumption. Detailed simulations help to develop environmentally friendly alternatives and reduce the carbon footprint – even at component level.
Further information and tips can be found in this article: The New Energy Efficiency Act – A guide for manufacturing companies with iPhysics
10. Connection of own technologies
The simulation software should provide a wide range of functions for high-performance work. However, as companies often have very different requirements for the simulation or want to integrate specific functions, the option of integrating your own applications via C# or C++ offers a clear advantage. Make sure that such individual extensions can be implemented without great effort and without high additional costs. This allows companies to incorporate individual requirements directly into the simulation, for example by integrating HMI solutions or specialized tools for production.
Discover the future of simulation today! Book your free web demo now and see how iPhysics can optimize your production processes with the latest simulation trends.
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Learn more about iPhysics and our virtual commissioning solutions on our website: www.machineering.com.
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Find out more about virtual commissioning and its benefits here www.machineering.com/en/virtual-commissioning
