<p>This thesis covers the development of a simulator for the Siemens Gas Tur-bine SGT-600. An explanation on how a gas turbine works is also given, as well as the principles behind the control system used by Siemens to control the turbine.</p><p>For Siemens Industrial Turbomachinery to be able to test its control sys-tem before delivering a gas turbine to the customer, a simulator is needed. The control system needs to be adjusted for every unique gas turbine, since there are several options for the customer to choose between when ordering the turbine. A control system standard is under development, which also needs to be tested in a simulator.</p><p>The framework for the simulator, i.e. the hardware and software that form the simulator system, was predefined to suit this specific purpose. The Siemens software SIMIT is used for developing the model. SIMIT is a real time simulation tool where models are constructed using blocks, similar to MATLAB Simulink.</p><p>A gas turbine is basically a heat engine that produces mechanical energy or electricity. The main task of the control system is to control the fuel flow to the combustion chamber and by that keeping the machine at desired speed.</p><p>The gas turbine model was developed using measurement data from a site in Hungary, where a gas turbine of the type SGT-600 is in service. The model is based on simplified relations between the signals. By analyzing measurement data and learning about the functionality of a gas turbine it was found out that the speed of the gas generator affected most other sig-nals, like temperatures and pressures. The gas generator speed was found to be dependent on the heat flow, which is determined by the openings of the gas control valves.</p><p>As a result of this thesis a working simulator for the gas turbine SGT-600 has been developed. The simulator can be used for testing the control sys-tem standard and for testing the control system when adapting it to a spe-cific delivery. It is also suitable for educational purposes, for example to instruct customers.</p>

This thesis covers the development of a simulator for the Siemens Gas Tur-bine SGT-600. An explanation on how a gas turbine works is also given, as well as the principles behind the control system used by Siemens to control the turbine. For Siemens Industrial Turbomachinery to be able to test its control sys-tem before delivering a gas turbine to the customer, a simulator is needed. The control system needs to be adjusted for every unique gas turbine, since there are several options for the customer to choose between when ordering the turbine. A control system standard is under development, which also needs to be tested in a simulator. The framework for the simulator, i.e. the hardware and software that form the simulator system, was predefined to suit this specific purpose. The Siemens software SIMIT is used for developing the model. SIMIT is a real time simulation tool where models are constructed using blocks, similar to MATLAB Simulink. A gas turbine is basically a heat engine that produces mechanical energy or electricity. The main task of the control system is to control the fuel flow to the combustion chamber and by that keeping the machine at desired speed. The gas turbine model was developed using measurement data from a site in Hungary, where a gas turbine of the type SGT-600 is in service. The model is based on simplified relations between the signals. By analyzing measurement data and learning about the functionality of a gas turbine it was found out that the speed of the gas generator affected most other sig-nals, like temperatures and pressures. The gas generator speed was found to be dependent on the heat flow, which is determined by the openings of the gas control valves. As a result of this thesis a working simulator for the gas turbine SGT-600 has been developed. The simulator can be used for testing the control sys-tem standard and for testing the control system when adapting it to a spe-cific delivery. It is also suitable for educational purposes, for example to instruct customers.

Vattenkraften är en viktig del av den svenska elförsörjningen och tillgodoser cirka 45 % av det årliga elbehovet i landet. Vattenkraften utnyttjar höjdskillnaden mellan inflödet och utflödet för att driva turbiner och producera el. I Sverige finns omkring 200 dammar med en fallhöjd större än 15 m och för höga nivåer vid någon av dessa skulle leda till ett dammbrott med omfattande konsekvenser. Ett viktigt område som det investeras mycket i idag är dammsäkerhet vilket går ut på att undvika okontrollerade översvämningar av dammen. Kännedom av fallhöjd och flöde är nödvändiga inom vattenkraft för att kunna beräkna producerad effekt och även vid dimensionering av dammar, vattenvägar och generatorer. Mättningar på inflödet till ett vattendrag anses vara mycket komplicerat och tidskrävande däremot kan utflödet genom utskoven beräknas med matematiska samband. Utskov avser öppningar i dammen som används för att avbörda vatten. Det finns således olika typer av utskov och det som påverkar valen är aspekter som kostnad, väderförhållanden, avbördningsförmåga, etc. För att undvika en möjlig överströmning av en damm dimensioneras ofta utskoven med avseende på vilken mängd vatten de bör avbörda. Ett krav som ofta ställs är att det ska vara möjligt att avbörda en vattendrags högsta vattennivå (HHQ). Några av de mest förekommande varianter av kontrollerade utskov i Sverige är valsdammar, luckdammar och bottenutskov.   Nivån i vattenmagasinet mäts upp med hjälp av sensorer som är placerade på olika platser vid dammen och uppmätta höga nivåer leder till att olika larmfunktioner löser ut. Regleringen av vattennivån sker då genom att avbörda vatten på ett kontrollerat sätt genom utskoven.  Genom att simulera regleringsprocessen av vattennivån i en virtuell miljö kan olika scenarier som kan uppstå vid magasinhantering testas på ett ekonomiskt sätt och hitta lämpliga reglerstrategier. Simuleringar är också en av de verktyg lyft fram inom industri 4.0 vilket kan bidra till framtidens lösningar inom automatiseringsprojekt. I arbetet studeras de olika beståndsdelar i ett vattenkraftverk och en tilltänkt metod presenteras för skapning av en virtuell modell av nivåregleringsprocessen i Siemens SIMIT, styrning av modellen via en virtuell PLC-enhet och visualisering av processen på en HMI-skärm. / Hydropower is an important part of the Swedish electricity supply and meets about 45% of the annual electricity needs in the country. Hydropower uses the height difference between inflow and outflow to power turbines and produces electricity. In Sweden, there are about 200 dams with a drop height greater than 15 m, and too high levels at any of these dams would lead to a dam break with extensive consequences. An important area in which a lot is invested today is dam safety, which is about avoiding uncontrolled flooding of the dam. Knowledge of drop height and water flow is necessary for hydropower to calculate the power produced and when dimensioning dams, waterways, and generators. Saturations on the inflow to a watercourse are very complicated and time-consuming, however, the outflow through the spillway can be calculated with mathematical correlations. Spillways refer to openings in the dam that are used to carry away water volumes. Thus, there are different types of spillways, and what influences the choices are aspects such as cost, weather conditions, etc. To avoid possible flooding of a dam, the spillways are often dimensioned with respect to the amount of water they should carry away. A requirement that is often made is that it must be able to carry away the highest water level (HHQ) of a watercourse.  The level in the water reservoir is measured with the help of sensors that are in different places by the dam and measured high levels lead to different alarm functions being triggered. The regulation of the water level then takes place by carrying away water in a controlled manner through the spillway. By simulating the regulation process of the water level in a virtual environment, different scenarios that can arise during reservoir management can be tested in an economical way and find suitable control strategies. Simulations are also one of the tools highlighted in industry 4.0, which can contribute to future solutions in automation projects. In the work, the various components of a hydropower plant are studied, and an intended method is presented for creating a virtual model of the level control process in Siemens SIMIT, controlling the model via a virtual PLC unit and visualizing the process on an HMI screen.

<p>In this thesis, a gas turbine simulator for the Siemens GT10C was developed and implemented. </p><p>It concerns everything from the theory behind the simulator; both the hard- ware and software involved, to how the actual simulator was built using these tools. The theory concerns itself with basic automatic control concepts, as well as basic turbine theory. </p><p>The simulator setup is being discussed concerning both technical and eco- nomic issues. A robust hardware solution is then selected, using the basic re- quirements, which the simulator then is built around. </p><p>The tools used are the Siemens SIMATIC automatic control system and the Siemens SIMIT real-time simulator using a SIMBA Pro PCI card to interface with the PLC:s in the SIMATIC system. Matlab are also used to a lesser extent to build the simulator behavior in SIMIT. </p><p>In the end, a fully featured simulator is presented that can be used for various purposes such as training operators, trying out new concepts and testing the automatic control system used to control the turbine. </p><p>Further development that could be done, by other engineers, in the future, is also discussed.</p>

In this thesis, a gas turbine simulator for the Siemens GT10C was developed and implemented. It concerns everything from the theory behind the simulator; both the hard- ware and software involved, to how the actual simulator was built using these tools. The theory concerns itself with basic automatic control concepts, as well as basic turbine theory. The simulator setup is being discussed concerning both technical and eco- nomic issues. A robust hardware solution is then selected, using the basic re- quirements, which the simulator then is built around. The tools used are the Siemens SIMATIC automatic control system and the Siemens SIMIT real-time simulator using a SIMBA Pro PCI card to interface with the PLC:s in the SIMATIC system. Matlab are also used to a lesser extent to build the simulator behavior in SIMIT. In the end, a fully featured simulator is presented that can be used for various purposes such as training operators, trying out new concepts and testing the automatic control system used to control the turbine. Further development that could be done, by other engineers, in the future, is also discussed.

Det traditionella sättet att programmera industriella styrsystem har alltid varit ettkostsamt och oförutsägbart sätt att driftsätta produktionsutrustning. Detta beror påatt styrsystemen programmeras parallellt med driftsättningen som sker sent iprojektet vilket inte ger mycket rum för misstag. I det här examensarbetet har enstudie gjorts på hur programvaran SIMIT kan användas för virtuell driftsättning.Genom att använda SIMIT för att skapa en digital tvilling som kan simulera signaler iproduktionen. Detta ska då leda till att programmeringsfel och design fel som annarskan uppstå vid en traditionell driftsättning kan minskas.Undersökningen inkluderade vilka typer av komponenter som är lämpliga attsimulera med hjälp av SIMIT. Hur SIMIT kan användas på bästa sätt för att skapa endigital tvilling som klarar av att simulera signaler i en produktion. Om det går attskapa en automatiskt genererad modell som är tillräckligt bra föra att användas i ettFactory Acceptens Test (FAT). Om det är möjligt att använda ett skript somautomatiskt testar digitala tvillingen med styrsystemen. Om det är möjligt attansluta SIMIT till ett Manufacturing Execution System (MES) och SupervisoryControl And Data Acquisition (SCADA) system. För att undersöka detta gjordesflera tester där olika funktioner i SIMIT användes för att skapa en digital tvilling aven monteringscellen.I undersökningen har flera olika sätt att skapa en digital tvilling undersökts där olikafunktioner i SIMIT har testats i delmoment. Utifrån resultaten har slutsatser dragitsbaserat på vilket sätt som är lättast, vilket sätt som ger bäst resultat och vilket sättsom fungerar.Slutsatsen av studien är att SIMIT är en lämplig mjukvara för att simulera signalernaför komponenter som inte har ett eget styrsystem t.ex. kameror, knappar, motorereller säkerhetskomponenter. Det bästa sättet att skapa en digital tvilling är attkombinera SIMIT med andra mjukvaror som kan simulera komponenterna som hareget styrsystem. Det gick inte att använda skript funktionen för att automatiskt testakoden för styrsystemen utan att ha en helt fungerande simulering för helamonteringscellen. I undersökningen av automatiskt genererade modell framgick detatt det inte gick att skapa en automatiskt genererad modell som gick att använda iSIMIT. I undersökningen av att simulera signaler från högre nivåer av automationssystemet som t.ex. MES och SCADA systemen, framgick det att det går att kopplaSIMIT till både MES och SCADA systemet. / The traditional way of programming industrial control systems has always been acostly and unpredictable way of commissioning production equipment. This isbecause the control systems are programmed in parallel with commissioning, whichtakes place late in the project, which leaves little room for error. In this thesis, astudy has been made on how the SIMIT software can be used for virtualcommissioning. By using SIMIT to create a digital twin that can simulate signals inproduction. This should then lead to a reduction in programming errors anddesigner errors that can otherwise occur in a traditional commissioning.The survey included what types of components are suitable to simulate using SIMIT.How SIMIT can be used in the best way to create a digital twin that can simulatesignals in a production. If it is possible to create an automatically generated modelsthat are good enough to be used in a Factory Acceptance Test (FAT). If it is possibleuse a script that automatically tests the digital twin with the control systems. If it ispossible to connect SIMIT to a Manufacturing Execution System (MES) andSupervisory Control And Data Acquisition (SCADA) system. To investigate this,tests were carried out to create a digital twin for an assembly cell.In the survey, several different ways of creating a digital twin have been done wheredifferent functions of SIMIT have been tested. Based on the results, conclusions havebeen drawn based on which way is easiest, which way gives the best results andwhich way works.The conclusion of the study is that SIMIT is a suitable software for simulating thesignals for components that do not have their own control system, e.g. cameras,buttons, motors or safety components. The best way to create a digital twin is tocombine SIMIT with other software that can simulate the components that havetheir own control system. It was not possible to use the script function toautomatically test the code for the control systems without having a fully functionalsimulation for the entire assembly cell. In the investigation of automaticallygenerated models, it appeared that it was not possible to create an automaticallygenerated model that could be used in SIMIT. In the investigation of simulatingsignals from higher levels of the automation system such as e.g. MES and SCADAsystems, it appeared that it is possible to connect SIMIT to both the MES and theSCADA system.

The Master’s thesis deals with virtual commissioning of the CNC machine tool changer. First deals with current state of knowledge with a systematic analysis of virtual commissioning. The 3D model is created by physical properties, sensors, actuators and control signals. In the last part of this thesis, a PLC program and visualization is created. The programs needed to create a virtual commissioning are jsou NX 12.0 - Mechatronic concept designer, SIMIT Simulation Platform V10.0 a TwinCAT 3.

The methods used today for the commissioning and validation of industrial machines requires theconstruction of physical prototypes. Those prototypes help the engineers to e.g. validate if theprogram code meant to control a machine works as intended. In recent years the development ofnew techniques for the commissioning and validation of industrial machines has changed rapidlythanks to the development of new software. The method used in this thesis is called simulationin the loop. Another method that can be benecial to use is hardware in the loop. Using thosemethods for the commissioning of a machine is called virtual commissioning. The simulation inthe loop method is used to simulate both the machine and the control system that operate thatmachine. This is called a digital twin, a virtual copy of the physical hardware and its control systemthat can be used without the need for a real prototype to be available.The software used in this thesis comes all from the company Siemens and those are TIA Portal,Mechatronics Concept Designer, SIMIT and PLCSim Advanced. By using those programs it waspossible to build a digital twin with rigid body dynamics and its control system of the industrialmodel that was given by the company Renholmen AB. This model contained all the necessarycomponents needed for a virtual commissioning project to be done without the need to be at thefactory oor.The results showed that it was possible to achieve a real time simulation, allowing the possibilityto trim the controller parameters without the need of a physical prototype. Design errors were alsofound thanks to the results of the simulation.This new technique has shown to be a useful tool due to most of the work could be done on a digitalmodel of the machine. Simulations can reduce the time to market for industrial machines and alsohelp engineers to validate and optimize the product at an early stage. This tool that can be usedto validate industrial machines before they are created.

The Master’s thesis deals with design of digital twins of machine tools and application of designed procedure on a case study – digital twin of the machine tool MCV 754 Quick. In the first part are described current roles of digital twins in the field of machine tools and also hardware and software options for creating them. Software and hardware tools by Siemens (Mechatronics Concept Designer and SIMIT) are used for the case study. The complex procedure of creating the digital twin is designed in the second part, starting with preparation of a model, ending with the virtual commissioning of the machine tool MCV 754 Quick. The procedure is described in detail, including preparation of 3D model of the machine tool, assignment of physical properties and joints, preparation of PLC, connection all the elements of the whole system: Sinumerik – SIMIT – Mechatronics Concept Designer and controlling the twin via CNC automation system. Output of the thesis is the virtually commissioned machine tool, capable of being controlled by Sinumerik 840D sl. This is the first step in development of the full-fledged digital twin of machine tool, which can be used for testing the functionality and capability of this new technology in industry.