Dev Report 01:
NexaTwin Mechanic Validation with Electronic Cam Manager
With this first Dev Report, we provide insight into the current development status of NexaTwin. One focus area we are currently working on is the Electronic Cam Manager within NexaTwin Mechanic Validation. The goal is clear: complex motion sequences should not only be tested on the real machine. They should already be built, tested, validated, and subsequently made usable for the real application in the digital twin. This way, NexaTwin evolves from a mere visualization tool into an engineering tool for true technical validation.
Why electronic cams are important in the digital twin
In many automation projects, motion sequences only become truly challenging when multiple axes, virtual masters, phase relationships, clock dependencies, and mechanical interconnections come together. On paper, a motion logic can appear clear. However, in the real machine, it often becomes apparent only late whether cam profiles, axis relationships, cycle behavior, and mechanical dependencies interact smoothly. A digital twin can help precisely here. Motion sequences become visible earlier, testable, and easier to understand.
What the Electronic Cam Manager is intended to achieve
The Electronic Cam Manager is designed to structure electronic cams and their associated axis relationships in the digital twin. This involves not only the representation of motion but also the technical validation of motion logic.
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Cam Profile Management
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virtual master axes
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Master-Slave Relationships
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automatic axle recognition in the digital twin
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Export for Real Drive Technology
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Control Mode and Viewer for observing curve logic
Cam Profile Management
A central component is profile management for electronic cams. Cam profiles can be created, saved, and subsequently edited. This allows motion profiles to be structured and reused. This is particularly important if motion logic is not only to be tested once, but is to be made usable across multiple scenarios, machine variants or real applications. The digital twin thus becomes not only a simulation environment, but a place where motion control logic can be systematically prepared.
Master Management with virtual master axes
Another key focus is master management. In the Electronic Cam Manager, virtual master axes can be created and their dependencies defined by phase and cycle. For example, master axes with different gear ratios such as 1:1, 1:3 or other ratios can be mapped. In addition, switching cams can be configured. This is particularly relevant when several movements depend on each other and cannot be considered in isolation. The digital twin makes these dependencies visible and testable earlier.
Slave Manager with automatic axis scan
The NexaTwin scans the digital twin for existing axes and makes them available in the Slave Manager as a catalog. This creates a structured overview of available axes in the model. Each slave axis can then be assigned to a cam profile, a phase angle, and a master axis. This supports a traceable assignment of motion profiles and axis relationships in the digital twin.
Export for real drive technology
An important step is the export of cam profiles for real drive systems. Individual profiles are to be exportable and reusable in real drive technology. In addition, the export of complete cam packages is planned. This allows motion logics to be transferred in a structured way from the digital twin to the real application. This is precisely where an important bridge is built between virtual validation and the real machine.
Control Mode and Viewer for controlling and observing
In Control Mode, the electronic cam can be driven directly, making it possible to actively test motion sequences in the digital twin. The viewer allows curves, axis dependencies, and master-slave relationships to be observed in interaction. This makes complex motion relationships not just calculated or configured, but visually and technically comprehensible.
Why Mechanic Validation is more than just visualization
For us, mechanic validation doesn't just mean beautifully visualizing a movement. It's about testing technical relationships earlier and understanding them more robustly. Especially with motion control applications, a pure 3D view is not enough. What's crucial is whether motion profiles, axis dependencies, phase positions, and real application logic fit together.
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to build complex movements early on
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Making connections visible
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To virtually test mechanics and processes
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Export results for the real machine
Conclusion: NexaTwin Becomes a Tool for Technical Validation
The Electronic Cam Manager represents an important development step within NexaTwin Mechanic Validation. It demonstrates how complex motion sequences can be built, tested, and prepared for real-world applications within the digital twin. This transforms NexaTwin from merely a visualization tool into a solution for genuine technical validation. From cam profiles and master-slave relationships to export for real drive technology, it creates a consistent approach to motion control in the digital twin. And this is just the beginning. With upcoming development steps like the NexaTwin Chain Simulation, real mechanical effects will be even better accounted for.