Programmed intelligence behind every automated action
Since 2015 Hypertec Solution has integrated an automation engineering team alongside its mechanical engineering division, maintaining continuous interaction between the two. The goal is to deliver a complete and reliable service in the development of automatic machines and industrial systems. Both teams collaborate throughout the full design cycle, from the analysis of technical specifications to the realization of the automatic machine as a finished and operational product. Thanks to this mechatronic synergy we are able to deliver fully customized and end-to-end engineering services. Our integrated approach enables thorough system-level control, predictive validation and design optimization ensuring robust performance and measurable project benefits.
Software design is undoubtedly a fundamental aspect of any industrial project in the field of machinery and automated systems, but it is not the only one.
We handle the analysis, development and testing of software applied to industrial automation systems. We also focus on production process control and plant supervision.
To optimize the synergy between mechanical design and software development for automatic machines and to reduce testing and commissioning times, we also employ advanced simulation systems in Virtual Commissioning.
Our company is built on cross-disciplinary expertise with a strong focus on innovation. Our working methodology allows us to deliver tailor-made solutions for every customer.
PLC – Safety – Motion Control
• B&R Automation Studio (*) qualified system integrator
• Schneider Electric PDM-PD3 (*) qualified system integrator
• Siemens Tia Portal
• Rockwell Automation Studio5000
• Beckhoff TwinCAT 3
HMI – SCADA
• B&R VC4 e MappView
• Schneider Electric Operator Terminal Expert
• Siemens Wincc – Unified
• Rockwell Automation Factory Talk View
ROBOTICS
• B&R Integrated Robotics
• Schneider Electric – Robotic NG
• Robot integrati in macchine e/o sistemi automatizzati: FANUC, KUKA, KAWASAKY, ABB
* We have been selected by B&R Automation as a Value Provider.
B&R has recognized us as reliable and specialized using their technology.
Our role in the sector is that of a System Integrator: we integrate the electronic components produced by B&R into the mechanical systems, enabling the machine to autonomously perform its functions.
B&R involves us in customized training programs, allowing us to expand our technical expertise and continuously stay up to date.
B&R’s excellence lies in its magnetic track systems. Exemplary is the new ACOPOS 6D based on the principle of magnetic levitation which is easily modular and scalable.
These systems are set to revolutionize the field of automatic machines and production plants.
The collaboration with B&R further amplifies what has always driven us: a forward-looking curiosity, a vivid imagination and a strong drive to innovate.
Virtual Commissioning is a technology that allows the dynamic and kinematic behavior of a machine or automated system to be replicated through software simulation. It enables the reconstruction of the behavior of one or more hardware components in a virtual environment and is used, as a complement to engineering design, as an advanced simulation tool.
The goal of an engineer working in Virtual Commissioning is to create a 3D digital model (digital twin) which allows the simulation of the application’s operation including all designed components. This simulation is performed by interfacing the model with the developed control software. The main advantage is the ability to identify, and correct, potential errors before the start of the manufacturing process for component production.
The purpose of this emulation is to anticipate the software testing phase while the machine or system is still in the design stage. The key advantage of Virtual Commissioning lies in the ability to eliminate errors even before producing individual components. The ultimate goal, of course, is to improve the quality of operations already during the design phase.
Virtual Commissioning enables a smooth transition from the virtual environment to the physical one reducing both testing and commissioning times.
How does Virtual Commissioning work?
Firstly, our engineers create a 3D model (digital twin) of the plant based on the CAD design, defining rigid bodies, the physical properties for simulation and kinematic constraints. Actuators are then specified to transmit motion to the various mechanisms, along with sensors for control signals and feedback.
Then, the model interacts with the control software developed on the same automation platform that will be used on the machine or plant. At this stage, a PLC or control system emulator can be used (referred to as SIL – Software In the Loop simulation), or a hardware CPU can be employed (referred to as HIL – Hardware In the Loop simulation).
This allows potential design errors in both the mechanical system and the control software to be identified and corrected before the mechanical components are produced and before the machine or plant is built and ready for actual commissioning.
Benefits of Using Virtual Commissioning
The use of Virtual Commissioning enhances the design and production phases delivering clear and substantial benefits. The most evident advantage is the reduction of time required for machine startup and testing.
Virtual Commissioning can also be used for commercial or marketing purposes. When a demonstrative presentation of a machine or plant operation is required, a virtual simulation can be used in advance. Another advantage of Virtual Commissioning is the possibility of using the model for training maintenance personnel and machine operators.
