Industry 4.0
  • Modelling of robotic cells
  • Simulation and virtual commissioning
  • Production optimisation
  • Diagnostics, model testing
  • Verification

Industry 4.0

The concept of Industry 4.0 (also called Smart Manufacturing) was introduced in Germany and represents a new paradigm in manufacturing which is based on closely interconnected processes during the whole product life cycle. Digital factory is the key element in Industry 4.0 and the integration of the supply chains, customer demands and feedback, diagnostics and monitoring of products after they leave the factory and are being used by the customers. A so called digital twin exists as a mapping of a real product during its life cycle to the world of product engineering, production, maintenance and recycling.

Industry 4.0 is not only a bunch of sensors spread over a technology monitoring the production conditions and sending the measured values to a cloud. Industry 4.0 is about information processing, data mining and decision making. It relies on advanced and intelligent systems that are capable of adapting themselves to the current requirements to satisfy the needs of flexible production and various customer demands.

Our services

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  • Analysis and optimisation
  • Development of user modules
  • Data model design
  • Virtual commissioning
  • Simulation control
  • Modelling of energy consumption
  • Manipulation with model geometries

Digital factory

A bundle of tools and applications that can synchronise product engineering, manufacturing engineering and production, is called digital factory. It allows designing and manufacturing innovative products in a fast and controlled manner. By direct connection and synchronisation between the product design and engineering phases, and manufacturing engineering the manufacturing process is leaner and more flexible.

Tecnomatix

Factorio Solutions is a Siemens PLM partner in the area of development for Tecnomatix Process Designer, Process Simulate, Plant Simulation, and Teamcenter. We specialise in creating customised user modules in Process Designer and Process Simulate. In Process Designer the focus lies in operations and data management and operations to provide the required functionality and complex views on the data. In Process Simulate our expertise lies in manipulating the simulation, analysing and evaluating the simulation results, processing and manipulating part geometries, managing objects in the database, and other required user functionalities. In relation to Virtual commissioning we offer services to control the simulation and analyse the results.

Plant Simulation is another product from the Tecnomatix family that is used for planning the manufacturing in terms of stream production. We offer services in creating the simulations, analysing the performance indicators such as throughput, buffer sizes, waiting times etc. and also various failure scenarios. In connection with a real PLC we can perform complete virtual commissioning.

Teamcenter

Teamcenter is a complete Product Lifecycle Management software that fully complies with the idea of digital factory and integrates a complete set of tools. The integration is not only functional but also data-based which means that any change in the product data is seamlessly available in the whole chain of product phases in its lifecycle.

Our services

Development of customised modules

Development of customised modules for Process Designer and Process Simulate.

Modules for simulation control and testing

Modules for simulation control and testing for Process Simulate and Plant Simulation.

Virtual commissioning

Virtual commissioning with Process Simulate and Plant Simulation.

Data model design and implementation

Data model design and implementation for Teamcenter.

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  • Connection of control systems to simulation
  • Parameterisation of safety-related features
  • Event-based simulation with a connected PLC
  • Hybrid configuration with other real devices
  • Continuous testing of PLC programs
  • Testing of correct fault handling
  • Automatic test generation
  • Model-based verification

Virtual commissioning

Virtual commissioning is a way how a production line can be commissioned without any physical installation on site. A prerequisite is to have a simulation of the production line in an environment such as Tecnomatix Process Simulate or Tecnomatix Plant Simulation. Such a simulation project can be connected to real hardware such as a PLC or any other control system. The biggest advantage of such a setup is that the control system is the same which controls the physical production line and no changes have to be done as soon as you switch from the simulation line to the physical one. In such a way even safety equipment such as emergency stop, safety light curtain, safety scanner or even safety functions of a robot can be part of the simulation in almost the same way as they are part of the physical facility.

Our services

Virtual commissioning as a service (VCaS)

Given a simulation study in Process Simulate or a project in Plant Simulation and a control program in a PLC, we evaluate various test scenarios on our equipment and provide the results to the customer. An online access for the customer is also available in order for him to be able to do continuous testing of the PLC programs. We also offer generating automatic test cases based on given user requirements.

Virtual commissioning as a product (VCaP)

We provide a proven hardware equipment that can run the control program for simulated production lines together with safety features. We offer automatic test generation based on given user requirements.

Workshops and user-specific training

Independent of whether you prefer VCaS or VCaP the workshops are useful to get basic hands-on experience about how to prepare simulation study in Process Simulate or a project in Plant Simulation, how to connect the control hardware and how to perform simulation with respect to virtual commissioning. The workshop is focused on applications that correspond to your field.

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  • Design of new Profinet networks
  • Throughput and load analysis
  • Commissioning of networks
  • Detailed analysis of network traffic
  • Modelling of network traffic
  • Predictive diagnosis and maintenance
  • More than 10 years of experience

Industrial networking and diagnostics

Profinet is a world-leading industrial Ethernet solution for various areas of automation. It is driven by Profibus & Profinet International organisation which tightly cooperates with technology providers and other manufacturers to offer solutions that satisfy the needs of end customers. One of the biggest user groups is the group of German manufacturers called AIDA that utilises Profinet-based solutions in its factories and production lines. Profinet is also suitable and utilised by machine builders because of its low-jitter and high-performance version called Profinet IRT.

Our services

Design and analysis of networks

Proper and careful planning is crucial for reliable operation of Profinet networks especially with mixed traffic. Our service of advance analysis contributes to such an objective.

Conformance tests

For a newly built Profinet network it is necessary to check if it complies not only with your requirements but also with the best practice recommendations. Our service of executing the conformance tests lowers the risk of future faults.

Fault finding and healthcheck

In a running network it may happen that faults occur (often irregularly) and disable correct functionality of the network and the related production technology. We do the analysis of the traffic and find the faults and their causes.

Long-term monitoring and diagnostics

In production networks it is useful to perform long-term diagnostics to monitor the key indicators that signal the "health" of the network. By regular monitoring and diagnosing the network and the communication it is possible to prevent faults that may cause drop-outs in production.

Device testing

Every Profinet IO Device needs to be certified by a PI Test Lab. We provide testing using official testing tools. We also develop one of the official testing tools that executes topology testing.

Device development

We offer the development of Profinet IO devices using specialised chips, various device stacks as well as customised solutions.

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  • Measurement and analysis of power consumption
  • Identification of operating modes
  • Modelling and simulation of robotic operations
  • Analysis of robot trajectories
  • Optimisation

Energy savings

In manufacturing robotic lines the robotic operations consume usually about 50% of the overall electrical energy. By optimising the robotic operations the production cost can be decreased significantly. A great potential is in optimising the trajectories that are executed by the robots. If they are smooth enough the necessary energy is lower. Another potential lies in the capability of the robots to be brought into a standby mode if they do not need to operate which may happen during planned pauses or even during unplanned pauses. Correct linking to a superordinate system is necessary for planning the standby. It is also possible to optimise the sequence of operations of the robots in order to lower their energy consumption.

Our services

Measurement of electrical power consumption

Using industry-grade power measurement cards we design the power measurement setup and store the data in a database with the sampling period of 40 ms which is the one the measurement cards are capable of.

Analysis of long-term and short-term data

The data stored in a database need to be analysed for various modes of operations, periods when the production is operated and when it is paused etc. We provide such an analysis.

Identification and diagnosis of robotic operations

As part of the data analysis we identify the robotic operations which serves for further diagnosis of the controlled process. This brings a detailed knowledge about the production cell and allows predicting its future behaviour or the necessity of maintenance etc.

Optimisation of robotic operations

We do optimisation of the robotic operations in terms of adapting the trajectories, designing the standby modes or optimising sequences of operations.

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Training

Well trained personnel is necessary for control and networked systems to be operated and maintained correctly. It is also necessary to be able to do the commissioning and to accept the delivery from a supplier.

Our services

Customised training of Profibus and Profinet

We provide training courses according to the requirements of the customer. We include the basics, advanced usage and diagnostics, fault finding etc. We also offer courses that are focused on specific customer products to study their behaviour from the point of view of Profibus or Profinet.

Training of other industrial networks

We can provide specialised courses on industrial networking in general to cover topics from various areas.

Training of control systems

We offer training of PLC programming by focusing on the basic principles as well as on the programming languages according to standard IEC 61131-3.

Contact

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Pavel Burget

+420 724 148 727
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Ondřej Fiala

+420 777 942 650