Schmersal Introduces Advanced 4D Digital Twins for Machine Safety

Schmersal is expanding its digital portfolio to include realistic 4D models of safety-related components, opening up new perspectives for virtual machine planning. These include the digital twin of the AZM40 solenoid interlock, the DHS door handle system and the BDF40 control panel. These 4D models not only depict the geometric properties of the physical components in three dimensions, but also add a fourth dimension: the behaviour in real operation. Components such as the AZM40 solenoid interlock are reproduced completely digitally and behave exactly like their real-life counterparts in virtual space. The virtual mapping of signal currents and control sequences allows complete machine processes to be simulated realistically.

Virtual commissioning as the key to efficiency
A key advantage of 4D models is the ability to commission machines and systems virtually - even before they are physically installed. This allows errors to be detected at an early stage, optimises development processes and saves costs. The possibility of connecting 4D models directly to real control systems, for example via Beckhoff or Siemens systems, is particularly noteworthy. In this way, system settings and control programs can be tested and optimised before actual commissioning takes place.




Standardised simulation: Schmersal relies on FMU models
One innovation is the availability of behavioural models as FMUs (Functional Mock-up Units). This enables standardised integration into different simulation environments such as Siemens Simit, the 3DEXPERIENCE platform from 3DS or ISG-virtuos. The FMU version of the AZM40 has already been successfully implemented. This significantly improves the interchangeability and reusability of the models – a decisive step for the scalability of digital twins in the industry.

AZM40 opens digital model catalogue in TwinStore
The 4D model of the AZM40 was also the first Schmersal component to be published and made available in the "TwinStore" – an online store for prefabricated and ready-to-use 4D simulation models. The release of the AZM40 as the first TwinStore package marks the start of a successive expansion of the Schmersal Group's digital model catalogue.

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