Creating a Digital Twin using Emulate3D

Summary

In this tutorial, Henry Gillan, a mechatronic specialist with ES&, demonstrates how to create a digital twin using Rockwell Automation's Emulate 3D software. The process involves importing a 3D model, utilizing the CAD as the model toolbar to create kinematic joints for linear motion, setting operational limits, and linking the model to PLC program tags for testing. This digital twin allows for virtual machine interaction and commissioning before physical construction.

Takeaways

• 😀 Henry Gillan, a mechatronic specialist with ES&, demonstrates creating a digital twin in Rockwell Automation's Emulate 3D using a CAD model.
• 🛠️ Emulate 3D is a software that enables the creation of a virtual working version of an automated machine for testing machine programs before physical construction.
• 📁 The first step is to import a 3D machine model into the e3D virtual environment, as shown with a simple two-axis gantry.
• 🔧 The CAD as the model toolbar is used to create joints that allow the virtual machine to interact with PLC program tags.
• 🔄 Kinematic joints are essential for defining the movement of the machine components; the script focuses on the kinematic prismatic joint for linear movement.
• 🔍 Selection of the correct visual component is crucial for applying physics joints within the nested model structure of the gantry.
• 📐 The direction of travel for the prismatic joint is defined using a translation wizard, associating with other parts of the machine.
• 🚫 Limits can be imposed on the model to constrain movement within a functional range, preventing operation outside normal limits.
• 🔄 Inverse kinematic allows for direct interaction with the model to test the defined behavior during simulation.
• 🔄 The Z beam joint must be mechanically tied to the gantry carriage, ensuring it moves along with the carriage.
• 🔄 Forward kinematic and distance mode settings are configured to allow PLC to write values and control the model.
• 🔌 The IO dropdown is used to expose the distance tag for connection with the PLC program, facilitating the integration of the digital twin with PLC for testing.

Q & A

What is the purpose of creating a digital twin in Rockwell Automation's Emulate 3D?

The purpose of creating a digital twin in Emulate 3D is to create a virtual working version of an automated machine, allowing users to connect to and test their machine program before the physical machine is built.

What is the role of the 'CAD as the Model' toolbar in the Emulate 3D software?

The 'CAD as the Model' toolbar in Emulate 3D is used to create joints that will allow the virtual machine to interact with PLC program tags, enabling users to define the behavior and interactions of different components in the machine model.

How does the kinematic joint feature in Emulate 3D work?

The kinematic joint feature allows users to define the direction of travel and movement for different parts of the machine model. It is used to create realistic interactions between components, such as linear up and down movements for a gantry system.

What is the significance of inverse kinematic in the context of the Emulate 3D software?

Inverse kinematic in Emulate 3D allows users to interact directly with the model, testing the defined behavior and movements. It enables the model to respond to user inputs, simulating the machine's behavior under different conditions.

How can users set operational limits for the model in Emulate 3D?

Users can set operational limits by entering an upper and lower limit for the model's movement and then enabling these limits. This constrains the model to move only within the defined functional range, preventing it from moving beyond normal operating limits.

What is the process for setting up a joint between the Z beam and the gantry carriage in the Emulate 3D software?

To set up a joint between the Z beam and the gantry carriage, users need to select the Z beam, define the joint as a kinematic prismatic joint, set the direction of travel, and then specify the gantry carriage as the base in the joint configuration menu. This ensures that the Z beam moves in conjunction with the gantry carriage.

How can users reset the model to its initial state in Emulate 3D?

Users can reset the model to its initial state by clicking the reset button, which stops the model simulation and resets the initial conditions as defined by the user.

What is the purpose of setting up forward kinematic for the Z beam in Emulate 3D?

Setting up forward kinematic for the Z beam allows the PLC to write values to the distance field and control the model. This is essential for integrating the digital twin with the PLC program for testing purposes.

How does the 'distance read from PLC' setting in Emulate 3D facilitate the connection between the digital twin and the PLC program?

The 'distance read from PLC' setting exposes the distance tag in the IO browser, allowing the PLC program to interact with the model by reading and writing values to the distance field, thus facilitating the connection between the digital twin and the PLC program.

What additional resources are available for users who want to learn more about virtual machine commissioning?

Users interested in learning more about virtual machine commissioning can check out the digital twin commissioning video provided by the same source, which offers further steps and insights into the process.

Outlines

00:00

🤖 Creating a Digital Twin with Emulate 3D

Henry Gillan, a mechatronics specialist, introduces the process of creating a digital twin in Rockwell Automation's Emulate 3D software. The video demonstrates how to use CAD as a model to build a virtual version of an automated machine, allowing for testing and connection to a machine program before physical construction. The tutorial covers importing a 3D model, utilizing the CAD as the model toolbar, and creating kinematic joints for machine interaction with PLC program tags. It also explains how to apply physics joints, set operational limits, and ensure components like the Z beam and gantry carriage move correctly and are constrained within functional ranges.

05:01

🔄 Configuring Joints for PLC Interaction

This paragraph delves into the configuration of kinematic joints to interact with a PLC program. It details the setup of forward kinematics for the Z beam and Gantry Carriage, enabling the PLC to control the model by writing values to the distance field. The process includes selecting appropriate IO options to expose distance tags in the IO browser, which is crucial for integrating with the PLC program tags. The video concludes with a prompt to view a digital twin commissioning tutorial for further steps in virtual machine commissioning.

Keywords

💡Digital Twin

A digital twin is a virtual representation of a physical object or system used to simulate, analyze, and optimize its real-world counterpart. In the video, Henry Gillan describes creating a digital twin using Rockwell Automation's Emulate 3D software, which allows users to test machine programs before the physical machine is built. This concept is central to the video's theme of simulating automated machines to verify functionality and performance.

💡Rockwell Automation Emulate 3D

Rockwell Automation Emulate 3D is a software tool for creating virtual models of automated machinery and systems. In the video, Emulate 3D is used to create a digital twin of a machine by importing a CAD model and simulating its interactions. This software allows users to test and optimize machine designs before construction, ensuring efficiency and accuracy in real-world applications.

💡CAD Model

A CAD (Computer-Aided Design) model is a digital blueprint of an object or system, created using specialized software. In the video, the CAD model serves as the basis for the digital twin in Emulate 3D, providing the structural framework for simulating the machine's components and interactions. This allows for accurate visualization and manipulation of the model within the software.

💡Kinematic Joint

A kinematic joint is a connection between two parts of a mechanism that allows relative motion between them. In the context of the video, kinematic joints are used in Emulate 3D to simulate the movement of a gantry system. By defining these joints, users can replicate the physical behavior of machine components and test how they interact within the digital environment.

💡Prismatic Joint

A prismatic joint is a type of kinematic joint that allows linear movement along a single axis. In the video, the prismatic joint is used to simulate the up-and-down movement of the Z beam and the linear travel of the gantry carriage in the Emulate 3D model. This enables the digital twin to mimic the physical operation of the machine accurately.

💡Inverse Kinematic

Inverse kinematic refers to a method of controlling a mechanism's movement by determining the joint parameters needed to achieve a desired position. In the video, this mode allows for direct interaction with the digital twin, enabling users to test how the model responds to various inputs. It is essential for ensuring that the virtual machine behaves as intended when controlled by external systems.

💡Forward Kinematic

Forward kinematic is a method that determines the position of a mechanism's end-effectors based on given joint parameters. In the video, forward kinematic is used in the prismatic joint menu for the Z beam to enable control via PLC program tags. This mode allows the digital twin to be controlled by external input, simulating real-world operational conditions and interactions with a PLC (Programmable Logic Controller).

💡PLC Program Tags

PLC program tags are identifiers used in a Programmable Logic Controller to represent variables and control elements within a machine's program. In the video, PLC tags are tied to the digital twin, allowing for simulation of the machine's behavior in response to real-time inputs. This connection between the digital model and PLC enables comprehensive testing and validation of machine programs before physical implementation.

💡Gantry System

A gantry system is a type of mechanical setup involving a framework that supports and guides movement along multiple axes. In the video, a two-axis gantry system is modeled in Emulate 3D, demonstrating the software's capability to simulate complex, multi-axis machinery. The gantry's components, such as the Z beam and carriage, are used to illustrate the application of kinematic joints and movement simulation.

💡Simulation

Simulation is the process of creating a virtual model to mimic the behavior of a real-world system. In the video, simulation is a core concept used to test the machine's operation in Emulate 3D before physical construction. By simulating various scenarios and interactions, users can identify potential issues and optimize machine performance, reducing the need for costly modifications after building the actual equipment.

Highlights

Introduction to Henry Gillan, a mechatronic specialist with ES&, who will demonstrate creating a digital twin in Rockwell Automation's Emulate 3D using CAD as the model.

Explanation of Emulate 3D as a software for creating a virtual working version of an automated machine to test machine programs before physical construction.

Demonstration of using the CAD as the model toolbar within Emulate 3D to create joints for virtual machine interaction with PLC program tags.

Step-by-step guide on importing a 3D machine model into E3D and accessing the CAD as the model toolbar.

Description of the physics options available in Emulate 3D for different component interactions, focusing on the kinematic joint for the two-axis linear gantry system.

Instructions on selecting the correct visual for modifying within the nested model structure of the gantry.

Tutorial on applying a kinematic prismatic joint for linear movement of the Z beam, including joint configuration and direction selection.

How to define the direction of travel for the prismatic joint using the translation wizard and model interaction.

Setting up operational limits for the model to constrain movement within a functional range.

Demonstration of model simulation with direct interaction to observe behavior and the imposition of movement limits.

Process of defining the X-axis joint for the gantry carriage using the prismatic joint and setting travel direction.

Explanation of setting up limits for the gantry carriage and the necessity of ensuring the Z beam follows the carriage movement.

Mechanical tying of the Z beam to the gantry carriage for synchronized movement during model simulation.

Resetting the model to its initial state using the reset button for reevaluation or correction of settings.

Final step of setting up new joints for interaction with a PLC program, including forward kinematic and distance mode setup.

Exposing the distance tag in the IO browser for PLC program tag integration and testing.

Completion of the digital twin setup for PLC program tag testing and a reference to the digital twin commissioning video for further virtual machine commissioning steps.

Conclusion of the tutorial with thanks for watching and a sign-off with music.

Transcripts

hi I'm Henry Gillan The mechatronic

Specialist with es& in this video I'm

going to show you how to create a

digital twin and Rockwell automations

emulate 3D using the cad as the model

[Music]

toolbar emulate 3D is a software that

can be used to create a virtual working

version of an automated machine what

this means is that you can use this tool

tool to connect to and test your machine

program before your machine is

physically built in this demonstration

I'm going to show you how to use the cad

as the model toolbar within emulate 3D

to create joints that will allow your

virtual machine to interact with your

PLC program tags let's get going first

you'll want to import your 3D machine

model into

e3d here you can see that I've already

imported a simple two AIS gantry

into the e3d virtual

environment once you've done this you

will want to click on the cad as the

model toolbar at the top of the software

window there's a whole Suite of physics

options available for different types of

component

interactions as stated earlier here we

have a simple two AIS linear Gantry

system so we're going to focus on the

kinematic joint when you need to apply a

physics joint you will need to make sure

you've selected the correct visual you

would like to

modify to do this you can select

hierarchy from the pane on the left side

of the screen and then select the visual

from the list this Gantry is part of a

nested model structure so you can expand

it out and hover over the different

components as you do you will see that

each piece is highlighted in the visual

so you can select the correct part we

will start with the Z beam once you

select the part expand the kinematic

joints menu and select the correct joint

since we are creating a linear up and

down Movement we will select kinematic

Prismatic joint you will see the joint

configuration menu pop up in the aspect

viewer window on the right side of the

screen click the Home tab at the top and

make sure you're in select mode when

you're in select mode you can click the

little box within the Prismatic Joint

menu this wizard will allow you to

define the direction of tra

of the Prismatic joint being created

once you've clicked on the translation

wizard box hover your mouse over the

model and select the direction of travel

as it Associates with the other parts of

the machine in the Prismatic Joint menu

under distance mode select inverse

kinematic this will allow you to

interact directly with the model and

test the defined Behavior now go back

into navigate mode and start the model

simulation here you can interact with

the model directly and see how it

behaves you can see that it moves up and

down correctly however I'm able to drag

it past the normal operating limits you

can impose limits on the model that will

constrain it to a functional range we

will enter an upper limit and a lower

limit and then enable the limits now you

can see that the model will only move

within the defined space now that we've

set up our Z beam let's define the

x-axis joint this time we will select

gantry carriage and again pick Prismatic

joint from the kinematic joints menu

again making sure you are in select mode

click the defined translation box in the

kinematic joint configuration menu for

the Gantry Carriage then select on the

model the direction and location of

travel put the distance mode into

inverse kinematic then go back into

navigate mode and start the model

simulation you can see the Gantry

Carriage oper Ates however we need to

set up limits and if you notice the Z

beam doesn't follow along with the

carriage like it should let's set our

limits first then we can fix the Z beam

again enter an upper limit and a lower

limmit and then enable the limits a

quick aside if at any point you want to

reset the model back to its initial

State you can simply click the reset

button and it will stop model simulation

and reset initial conditions as defined

we want the Z beam to always be

mechanically tied to the Gantry Carriage

so if we go back to the Z beam joint

configuration menu we will see that

there's no defined base so as the base

we will simply type in Gantry carriage

and select the visual from the dropdown

now if you run the model you will see

that the joints operate independently

however the Z beam is always tied to the

Gantry Carriage as it moves along the

last step is to set up the new joints so

that they can interact with a PLC

program back in the Prismatic Joint menu

for the Z beam select forward kinematic

for the distance mode this will allow

the PLC to write values to the distance

field and control the model second in

the io dropdown select distance red from

PLC this will expose the distance tag

and place it in the io browser for when

it's time to tie in the PLC program tag

you can then perform the same action for

the Gantry Carriage that's it now you're

ready to tie your digital twin to PLC

program tags for

testing be sure to check out our digital

twin commissioning video for the next

steps in virtual machine commissioning

thanks for watching

[Music]