Case Study · Virtual Commissioning
VDL Steelweld: Creating Smart spaces with RF::SUITE
How VDL Steelweld Optimized the Highly Variable Smart Space Wall Assembly Using Virtual Commissioning
Project overview
How VDL Steelweld Optimized the Highly Variable Smart Space Wall Assembly Using Virtual Commissioning
By using virtual commissioning, VDL Steelweld was able to efficiently optimize the automation process of its automated wall assembly line for VDL Smart Spaces while minimizing time and cost risks.
Customer background
CUSTOMER BACKGROUND
The task
CHALLENGE
High variant diversity and short cycle times
With an annual production volume of over 2,500 modules, it is crucial to virtually validate all possible product limits and their respective cycle times during the commissioning phase. This ensures that the ongoing production process can manufacture the market-demanded modules error-free and on schedule.
High product variety and customization
The production line is designed for a wide range of wall modules with different dimensions and specifications. Thanks to the modular construction, lengths from 300 mm to 7,000 mm in 1-mm increments are possible. This flexibility allows for the production of over 1,000 variants and ensures high adaptability to specific customer requirements.
Integration of hardware and software
During the commissioning of the Smart Spaces wall assembly line at VDL Steelweld, hardware and software components had to be precisely integrated and synchronized. Without simulation, the high number of variants could lead to unexpected errors. The process control was managed via a Siemens S7-1500 PLC, while four Fanuc robots handled motion and process control.
System complexity and material flow
The production line includes several automated process steps with a complex material flow. Coordinating the individual components and ensuring their flawless interaction is essential for smooth production.
Time pressure and potential production delays
The tight timeline for commissioning the line required a fast and error-free implementation. Unexpected problems during physical commissioning could lead to significant delays and costs.
Error strategy
Proactive error detection and prevention were necessary to avoid costly downtimes and rework. Virtual commissioning enabled early identification of potential issues and optimization of the control system before the actual commissioning.
Digital validation
SOLUTION
VDL Steelweld, together with EKS InTec, implemented virtual commissioning using the RF::Suite to digitally replicate the Smart Spaces wall assembly line. The team integrated all hardware and software components—including the Siemens S7-1500 PLC and four Fanuc robots—within a virtual environment, accounting for the full range of product variants and complex material flows. By simulating the entire production process in advance, the control logic, movement sequences, and interactions between line components could be precisely programmed and validated before physical commissioning. This approach ensured a fully integrated, error-checked system ready for real-world operation, while maintaining the flexibility needed to handle the high variety and customization of modular wall modules.
Measurable impact
BENEFITS AND RESULTS
By using VIBN and RF::Suite, VDL Steelweld achieved significant progress in production:
On-site commissioning was made much more efficient, allowing faster production start-up.
Many issues were resolved in advance, significantly reducing the effort required for real commissioning and minimizing costly rework.
Movement sequences, material flows, and control logic were efficiently tested and optimized, increasing the real line’s productivity.
Potential sources of error were identified early in the virtual environment, significantly reducing the risk of unexpected issues during real commissioning.
The control software was fully developed and verified in the virtual environment, ensuring smooth real-world operation.
With RF::Suite, various production scenarios could be simulated, reducing the need for on-site testing and accelerating fine-tuning of production processes.
“With Virtual Commissioning and RF::Suite, we optimized our commissioning, identified errors early on, and saved valuable time and costs. A real improvement in efficiency and quality”
Beyond the project
CONCLUSION AND FUTURE OUTLOOK
Virtual commissioning not only optimized automation in the production of modular living units at VDL Steelweld but also demonstrated that this technology is highly beneficial beyond the automotive sector. It helps to standardize processes, minimize errors, and increase efficiency across various manufacturing domains.