Towards shorter validation cycles by considering mechatronic component behaviour in early design stages

Nowadays typical validation in the development process of automated production plants includes Virtual Commissioning (VC) to test the control logic against the modelled plant behaviour. To reduce modelling efforts, the generation of models for VC is in practical often based on the existing control logic, e.g. hardware configuration of the PLC (used for automated signal mapping). This results in the limitation of testing at the end of the development process with resulting disadvantages like late detection of errors. In the meantime early automation concept evaluations are mainly done by empirical knowledge due to the lack of reliable models. In this paper we will present a component model and work-flow for coupling a 3D-CAD tool with a behavioural model of a mechatronic component for generating an initial virtual plant model allowing examining the feasibility of the selected components already during the mechanic design phase. The created model could also be used for iterative development of the control logic with an comprehensive VC at the end of the process utilizing the already developed model and thus reducing modelling efforts and enabling shorter validation cycles throughout the whole process.