At its fullest potential, simulation-based design promises the capability to make better products in a faster and cheaper way, with all the mistakes and tweaking done in a virtual environment. In this forum, Motion System Design editors ask industry experts for advice on how to make the most of current modeling and simulation tools, and what we might expect to see in the future. Following are the responses we think you'll find most valuable.

TO WHAT EXTENT IS IT NOW POSSIBLE TO MODEL AND SIMULATE THE OPERATING DYNAMICS OF INDUSTRIAL MOTION SYSTEMS CONSISTING OF MULTIPLE MECHANICAL AND ELECTROMAGNETIC COMPONENTS?

Thomas • Bosch Rexroth: From a standpoint of available tools, a wide range of simulation is already possible. But the engineering level concerning how it must be used is still at a very academic level. No truly integrated packages exist that combine the necessary device libraries, which would allow an engineer to easily model and simulate a complete production system.

Steve • Rockwell: Current technologies allow for the modeling and simulation of highly complex industrial motion systems with multiple mechanical and electromagnetic components. Today's leading simulation packages provide libraries of core functions that let designers create the basic system building blocks. As these models are cascaded together with the other model components, entire machines and processes can be emulated to allow for total system simulation.

Synchronization methods are also available that allow plant model simulation to be coordinated with a model of the user's control system. By running the simulated control system in synchronization with the user's plant function, an entire system — from control to process — can be emulated, allowing for easy troubleshooting, diagnostics, and system design.

Marius • Ansoft: In general, the design and simulation of industrial motion systems is often compromised by the sheer complexity of the inherent subsystems: power generators, rectifiers, converters, and electromechanical and hydraulic loads. In the past, engineers attempting to simulate these systems have been stymied by the need for expertise and understanding of all the subsystems and their interactions. Overwhelmed by the complexity of the task, many engineers revert to an expensive "build and test" methodology rather than fully employing the power of simulation.

WHAT ARE SOME OF THE ADVANTAGES ASSOCIATED WITH SYSTEM-LEVEL SIMULATION FOR DESIGNERS AS WELL AS END USERS?

Marius • Ansoft: Components and systems must be tested in an environment emulating their intended use to enable refinement of system requirements, design decisions, and efficient resource utilization while ensuring that designs adequately address the operator's needs. Systemlevel simulation provides a proven, cost-effective research capability. It will contribute significantly to the safety and success of the product design stage through virtual hands-on experience.

Steve • Rockwell: System-level simulation opens the doors to flexibility, exploration, and analysis of system design and system behaviors. Once individual components and functions have been proven and validated, each function can be used over and over again from one design to another. These components serve as the building blocks of the system design — and are all "paper designs;" they don't commit the designer or user to buying expensive pieces of machinery in order to determine if a concept will actually work.

By moving the various pieces around in a virtual reality, design, troubleshooting, and analysis are all possible without buying a single bolt or screw. This saves time and money, and provides an environment for experimentation that was not previously available to most in the industry.

Thomas • Bosch Rexroth: System-level simulation allows equipment designers to model and test different scenarios and alternative machine designs, and run complete tests to determine functionality and efficiency without wasting any hardware or machining and assembly time.

Reconfiguration of simulated systems as compared to real-life machines is easy and the risk for the involved equipment is close to zero. End users can use system-level simulation to build up machines and production lines on a modular base, and "play" with different approaches for a set production requirement. Production optimization can take place before real-life equipment even exists.

System-level simulation also has great potential for training and education. With completely simulated machines, operators, programmers, and service personnel can be trained on new machines or for new production processes prior to working with real equipment.