Methodology for virtual commissioning based on object-oriented behavioral models with a selectable modeling depth

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The modeling process required for the virtual commissioning is very complex and hence often neutralizes the benefits of a shorter commissioning time. Therefore, the overall target of this project is to establish a new methodology for the virtual commissioning of engineering plants based on object oriented models. The methodology is based on modular structured engineering plants. For these modules behavioral models are created with variable and adaptive changeable modeling depth. Furthermore, the methodology includes development systematics for the integration of virtual commissioning in the process of plant engineering and a development environment.Modeling the behavior of the plant modules is conducted in four defined modeling depths. These differ in their degree of abstraction, ranging from the illustration of the idealized function of discrete-time state machines to the highest detail for component optimization. In an interface model, the interfaces and parameters of behavioral models are defined. Thereby the modular design of the behavioral model of the entire system is possible. The behavioral models of individual modules can differ in their model class (e.g. FEM, MBS) and have different modeling depths. Furthermore, for the modules a manual as well as an automatic switch between the associated behavioral models with different modeling depths is possible. The user is supported by a method for the selection of modeling depth and model class.The development systematics consist of a procedural model, methods and tools. The procedural model describes the process of plant engineering on the basis of model-based design of mechanical systems and integrates the virtual commissioning. It focuses on the construction of behavioral models and testing of control programs. Furthermore, it controls the use of the developed methods and tools. Test scenarios are developed for the assessment of the control programs already in the conceptual design of the plant, which results in requirements for the behavioral models.The development environment supports the integrated construction of behavioral models of different model classes and modeling depths. A model library provides the structured storage and enables the reuse of created models.The project results will be validated with two demonstrators:1) Flexible material flow system of type Montrac (Co. Montech www.montech.com)2) System for automated dough production (Co. WP Kemper, www.wp-kemper.de)The methodology enhances the benefits of behavioral models for virtual commissioning, since the models find application in the entire process of plant engineering. The efforts necessary for creating the behavioral models are reduced to a degree of abstraction that is appropriate for the requirements.