From virtual to real – building automation that works

In automation, reality ultimately means the environment where systems are installed and put into operation. That’s where they need to perform – and where they create value for our customers.

Long before that, however, the automation system exists in a virtual form, often months before it is physically built. All our systems are fully designed in 3D CAD, giving us a complete model of how the installation will look and function. In this environment, we test reach, accessibility, and all mechanical movements.

We also bring every model into ABB’s simulation environment, RobotStudio, where we can thoroughly test robot movements, measure cycle times, and see the robot cell in motion. The capabilities of this tool continue to grow, and today we can also include physical properties such as gravity and friction. This allows us to drop or tip products virtually – insights we previously could only gain in real-world testing.

Testing before delivery

After the virtual phase, all our automation systems are physically assembled in our own facilities for testing, trial runs, and continued programming before delivery to the customer. Testing performance and functionality before shipment has proven crucial to successful projects. We therefore place great emphasis on fine-tuning and testing under conditions that are as close to reality as possible.

Test runs are concluded with a formal Factory Acceptance Test (FAT) together with the customer. This includes approval of everything from functionality and finish to documentation and cable labeling. Once the system has passed this test, it’s ready to meet the customer’s reality.

When reality already exists

One potential challenge arises when the system is installed on site and must fit into an existing production environment. Structural columns, ventilation ducts, overhead cranes, and other machinery may already be in place. Predicting how a large, three-dimensional “puzzle piece” will fit into that environment – without collisions and with good ergonomics for operators – is not always easy.

3D scanning brings reality into the design phase

This is where 3D scanning becomes an invaluable tool. By scanning a facility, we create a detailed 3D point cloud that captures the customer’s real production environment with impressive accuracy – often within a few millimeters.

Modern tools allow the point cloud to be hosted on secure web servers, giving relevant stakeholders access to virtually visit the site multiple times during the design phase. In our experience, this is a major advantage. Designers can measure distances, check heights, and examine details as the new system takes shape.

Once our automation system is complete in the CAD environment, we can place the entire model directly into the 3D point cloud. This allows us to see exactly how it will fit into the existing environment long before components are ordered or anything is built physically. At this stage, adjustments are relatively simple and cost-effective – whereas similar changes later in the project can be complex, expensive, or even impossible.

We’ve also seen how this approach improves collaboration with our customers. For many, it becomes much easier to understand how the system will look and function when they see it placed directly into their own production environment.

Digital twins for development and installation

3Button Group has participated in a three-year research project together with industry partners, academia, and RISE, aimed at helping small and medium-sized companies adopt 3D scanning and point cloud technology. The project had a total budget of approximately SEK 10 million, with half funded by Vinnova.

Through this work, we’ve gained valuable insights, and today we see 3D scanning and point clouds as a natural part of our toolbox. Not every project requires scanning, but for some – particularly larger production systems that must integrate into existing environments – it has become an invaluable asset.

The response from our customers has been overwhelmingly positive. Many have also found new uses for the point cloud in other processes beyond the automation project itself.

If you’re interested in this technology and would like to explore scanning your own factory, feel free to contact us. We’re happy to share our experience, offer guidance, and assist with the scanning process if needed.