In the field of Computer Aided Manufacturing (CAM) solutions are required for the simulation of entire production environments including all hardware and software components inside an installation. In this regard, the so-called Digital Plant became more and more important. Several tools based on simulation techniques exist which support the developing of new production automation solutions and factories. In contrast to this, we introduce an innovative approach to realize the Digital Plant. Rest upon 3D graphical simulation we are able to process enlarged simulation models using distributed computing of the complex environment. The flexibility of the evolved interface between simulator's instances facilitates the coupling of other simulation tools to our system. Adapted from the identical interface we connect real controller systems to the partitions to simulate production control. The integration of the different software components extends the use of manufacturing simulation. In this article, we focus on distributing and simulating complex models to establish the base of the Digital Plant.

Simulation techniques in the area of manufacturing automation have become more and more important. Thus, there are several tools available for planning and offline-programming of automated production processes. We describe an innovative universal simulation system, called COSMIR/sup /spl reg// Factory. Based on a unique approach to parallel simulation this tool extends the use of manufacturing simulations. On the one hand, the presented system facilitates the simulation of complex manufacturing processes. On the other hand, the once developed simulation model is suited for further applications like 3D process visualization, teleservice, and virtual training of operators. Beside the technical description of the system's architecture, we present a practical example comprising the simulation of a production line and the connection to a superimposed controller.

3D simulation and flexible control of robot-based workcells are in common use. However, many companies, especially SMEs, do not make use of the advantages these technologies imply. Reasons for this behavior are the costs of the software and hardware systems as well as the fact that one needs experts to operate those systems. This article describes an innovative architecture that has been developed for a corporate integration of simulation and control systems into production processes. The coexistence and cooperation of PC-based simulation and control makes the cost-effective use of virtual reality (VR) methods and a wide range of novel industrial applications possible. By use of VR technologies complex systems can be operated by any user without long periods of training. Thus, small- and middle-size companies are enabled to use innovative technologies to increase their productivity and competitiveness.