Ahead through foresight: How the digital twin is revolutionizing mechanical engineering with twin – Insights from K&S Anlagenbau GmbH

In a world where precision and speed determine market success, mechanical engineers face the constant challenge of implementing increasingly complex systems in ever shorter times. Any planning errors in the concept phase cost valuable resources, and any delays in commissioning jeopardize the success of the project. K&S Anlagenbau GmbH, a master of highly specialized production lines, has turned this pressure into a strategic advantage. Its tool: the twin simulation software from digifai, which brings the digital twin to life from the first sketch to ongoing operation.

K&S Anlagenbau GmbH builds highly specialized production lines. For example, one reference system processes 5,500 individual parts per minute on 32 tracks.

To understand the performance capabilities of modern plant engineering, just take a look at a reference plant from K&S: 5,500 individual parts are fed onto 32 tracks per minute and processed into over 500 finished components per minute. With such a throughput, it is clear that classic trial-and-error methods are not an option during commissioning. The risk of collisions, cycle time conflicts, and undetected logic errors would be immense. This is precisely where K&S’s strategy comes in: end-to-end simulation that safeguards the entire development process.

Even before a single component is manufactured, the plant is created in twin. “We already use twin in the concept phase and in domain-specific developments for various specialist areas. The long-term goal is virtual commissioning, which can also be implemented with twin,” says Fabian Böck, Simulation & Software at K&S Anlagenbau GmbH, summarizing the integrative approach.

“We already use twin in the concept phase and in domain-specific developments for various specialist areas. Even—or especially—in our special machine construction division: the long-term goal is virtual commissioning!”
Fabian Böck – Simulation & Software, K&S Anlagenbau GmbH

A key advantage is the ability to draw on a proven modular system. Existing, optimized assemblies can be imported into new projects as digital modules. This creates a powerful library that dramatically speeds up the design of new systems. Even complex track systems, in which objects are moved along defined paths, can be precisely simulated and validated. The result: a robust machine concept that has already been thoroughly tested digitally.

In the next phase, the 3D CAD data is used to create a digital twin of the entire machine or at least a high-risk section of it. This digital clone is more than just an animation; it has exactly the same actuators and sensors as its real-life counterpart.

The decisive step for the future: connecting the real control systems (PLC). For the control systems, there is no difference between the digital twin and the physical machine. Engineers can develop, test, and optimize the entire control software while the real machine is still under construction.

• Parallelization: Software development and hardware manufacturing run in parallel, not sequentially.
• Risk-free testing: Every conceivable scenario, every possible cycle time variant, and every conceivable malfunction can be safely simulated. Collision tests and the optimization of motion sequences are carried out on the model.
• Absolute security: The software that will later be installed on the system has already been 100% tested in conjunction with all components.

Virtual commissioning with twin has an impact far beyond the development department.

• In sales: A sales engineer can present potential customers not only with drawings, but also with a running virtual machine. This builds trust, visualizes the solution, and minimizes the risk of cycle time analyses in the quotation phase.
• For retrofitting: Existing systems must be flexibly adapted for new products. With twin, these modifications are first planned and simulated on a 3D model. This guarantees that the adapted machine will restart quickly and smoothly—a decisive factor for flexible production in line with Industry 4.0.
• During operator training: Staff can be trained on the animated, interactive model long before the actual machine is installed. This identifies potential usability issues at an early stage and ensures a smooth start to production.

In summary, Mr. Böck reports on the successful implementation in the company:

“When K&S began development a few years ago, digital twins were a trend. We were surprised ourselves at how quickly and reliably the method could be applied, and suddenly it spread from department to department. Now we even simulate the sorting of individual parts before we build a feeding system.”
Fabian Böck – Simulation & Software, K&S Anlagenbau GmbH

The shift of commissioning efforts to the digital world of engineering is not an end in itself. It leads to tangible economic benefits. Stefan Kirchbihler, authorized signatory at K&S Anlagenbau GmbH, sums it up:

“The commissioning phase is shifting to the engineering stage, which results in significant cost savings. This makes it possible to reduce project lead times by up to 20%.”
Stefan Kirchbihler – Authorized Signatory, K&S Anlagenbau GmbH

This increase in efficiency, combined with enhanced process reliability and flexibility throughout the entire life cycle of a plant, makes twin an investment in the future viability of the company.

Contact us now and discover how the leading simulation software twin can take your mechanical engineering to the next level. Say goodbye to costly surprises during commissioning and gain a decisive competitive edge.