Rockwell and Ansys Partner to Combine Industrial Control Systems and Simulation Tools

September 22, 2021 by Stephanie Leonida

Rockwell Automation announces that its Studio 5000 Simulation Interface is now able to connect with Ansys Twin Builder.

Rockwell Automation recently announced a new development with its Studio 5000 Simulation Interface. The interface is now able to connect with the Ansys Twin Builder. This new partnership allows automation and process engineers to design applications for real-world use with a digital replica to improve design and performance. 

An engineer working with ANSYS simulation tools. Image used courtesy of Ansys


Rockwell’s Studio 5000 Simulation Interface

Engineers that use the Studio 5000 Simulation Interface can connect the application program that they created in the 5000 Logix Designer with a third-party simulation or model of the application that can be tested. 


The 5000 Logix Designer interface. Image used courtesy of Rockwell Automation 


The ability to test applications with a simulation can reduce material costs and development time. A controller program created for a complex application such as a turbine can be tested, debugged, and improved. Engineers can skip building a prototype and avoid using a physical live system. 


Ansys Twin Builder

Ansys, Inc. is a U.S. company that supplies and develops computer-aided engineering (CAE)/multiphysics engineering simulation tool designed for testing, product design, and operation. Ansys Twin Builder allows engineers to create, validate, and deploy a tailored simulation-based digital twin in the cloud or on edge.

A digital twin is a system designed to mimic the behavior of the physical thing it represents. A digital twin is created from an accurate representation of a physical product or process. There are many different use cases for digital twins in industrial automation today, including in industries such as oil & gas, aerospace engineering, electronics, and more. 

The Ansys Twin Builder can embed performance information of simulation-based digital twins and can help engineers cut run times from weeks to hours. 

Engineers can use the Ansys Twin Builder for applications such as battery management systems and electric/hybrid vehicle powertrain design. Image used courtesy of Ansys 


In a recent press release, the Business Manager at Rockwell, Julie Robinson, commented, “By connecting a control system to Ansys Twin Builder, users can simulate complex physical processes and give realistic inputs to the control system.” Robinson added, “This can provide tremendous insights throughout the equipment lifecycle. For example, running a simulation model in parallel to a physical system during production can reveal opportunities to optimize performance in real-time.”


Combining Industrial Control Systems with Simulation 

By using the Studio 5000 Simulation Interface with the Ansys Twin Builder, simulations can be compared with their real-world counterparts to make improvements. The user can then calculate the remaining life of a systems component and replace those components if necessary to avoid any unwanted downtime. With added digital twin capabilities, this combined technology may helo engineers and automation experts optimize production, increase safety, reduce costs, and increase time-to-market. 

Rockwell Automation and ANSYS hope this partnership will provide users with the control system technology and simulation techniques needed to expand their capabilities.