The digital twin in the process industry today offers very extensive options for simulating system performance. The simulation of the power electronics, but also the drive system with the connected machines, are important tools for optimizing the system. For this purpose, real-time simulation based on hardware-in-the-loop (HIL). HIL is a testing procedure in which real physical components or subsystems, such as controls, automation, are integrated into a virtual simulation environment.

In the application for platform electrification to reduce CO2 emissions, the system performance is simulated and verified in real time in all relevant operating modes. M2C converters were used, which have particularly network-friendly properties due to the converter topology. The behavior in the event of possible malfunctions such as asymmetrical short circuits on both the network side and the consumer side is simulated and the behavior of the entire system is optimized on the platform. For this purpose, HIL simulators were set up for the relevant systems and simulations were carried out in real time.

In another example, the behavior of an LCI converter including a compressor load in the event of asymmetrical network drops could be examined and optimized. Here, with the help of HIL simulation, the performance of the system could be significantly improved and proven.

The investigations show that simulation tools such as HIL enable significant optimization of the performance of the VSD or SFC system, which would only be possible to a limited extent or with a high expenditure of time and money with conventional tests in test fields or during commissioning.