Virtual commissioning

Detect early, resolve fast, enhance efficiency and commission virtually.

Accelerated project timelines

Speed up design-to-deployment, identify and fix issues virtually, bypassing traditional commissioning delays.

Cost reduction

Reduce expenses by minimizing physical prototypes and streamlining on-site testing processes, leading to significant savings.

Enhanced collaboration

Collaborate efficiently with synchronized development and testing, streamlining the commissioning workflow.

Virtual commissioning in manufacturing

Virtual commissioning is transforming manufacturing by enabling early testing of machines and systems, crucial for meeting factory acceptance testing (FAT) deadlines. This approach reduces delays, costs and compromises, offering a transformative way to test and debug control software. Unlike traditional methods that delay testing until hardware assembly, virtual commissioning allows for earlier control software testing, like in Programmable Logic Controllers (PLCs) and virtual robot controllers, streamlining the commissioning phase and changing the conventional sequence of events.

Process and benefits

Virtual commissioning begins with a detailed static 3D CAD model, incorporating motion dynamics and control systems. This process, different from digital twins, brings benefits like increased efficiency, cost savings, enhanced safety and quality, and collaborative work environments.

It is useful in various manufacturing applications, from automation to complex packaging simulations. The comprehensive process includes developing a virtual model, system analysis, integrating kinematic and electrical data, control logic, simulations, robotics optimization and iterative refinements for optimal performance.

The role of virtual commissioning in digital transformation

By facilitating early problem identification and resolution, virtual commissioning can help enhance operational efficiency and is essential for modern manufacturing – helping maximize ROI and being a transformative element in developing advanced, efficient, and reliable manufacturing systems all from the comfort of your office (or wherever you may be).

Visual Components offers the necessary tools and expertise for virtual commissioning.

Virtual commissioning with Visual Components

How do you get started with virtual commissioning? Here, we provide a step-by-step example using Visual Components to help you get started.

Model development

Create an accurate virtual model using CAD data and other resources (like the eCatalog), ensuring it’s detailed and closely aligned with the real-world design.

System analysis and building

Perform a detailed analysis of the system and build the virtual model to include kinematics, electrical data and integrated control systems.

Control integration

Integrate control logic into the model, ensuring it accurately reflects the actual control systems used in physical machines.

Virtual robot controller integration and programming

In robotics projects, integrate virtual robot controllers into the model. Program robots to perform tasks virtually, ensuring that the programming and control logic stay in sync.

Simulation and testing

The platform’s intuitive ‘drag and drop’ functionality lets you position each component where it best suits your operations. Rearrange, adjust and settle on a design that maximizes space utilization and efficiency.

Robotics optimization

In robotics projects, robots performance should be optimized to ensure efficient installation and operation. Virtual programming involves refining robot movements and tailoring tasks for enhanced efficiency, speed and product quality.

Iterative refinement and safety checks

Refine the model iteratively based on test results for optimal performance and conduct rigorous safety and compliance checks.

Physical commissioning and continuous improvement

Complete physical commissioning to validate the system’s real-world behavior and engage in continuous improvement by comparing operational data with virtual commissioning outcomes.

Documentation and future reference

Thoroughly document the entire process, which is vital for future reference, troubleshooting, system upgrades or scaling of operations.

For robot programmers

Optimize robot programs virtually to reduce on-site programming and commissioning effort.

For manufacturing engineers

Quickly design, optimize and adjust layouts with minimal training to test what-if scenarios and minimize risks.

For production managers

Accurately optimize process and mitigate risks to maximize efficiency according to your operational needs.

For system integrators

Improve planning, decision-making and sales processes to boost productivity, reduce errors, enhance collaboration and customer engagement.

How are our customers using Visual Components for virtual commissioning?

Wächter Packautomatik: navigating variations in furniture packaging

Learn how Visual Components helped demonstrate and streamline furniture packaging solutions at high speeds.

Invio Automation: simulating automation in the manufacturing of windows

Learn how Visual Components helped evaluate concepts to increase throughput while maintaining or reducing overall direct labor.

Etteplan: designing turnkey solutions for customers

Learn how Etteplan uses Visual Components manufacturing simulation for business growth by providing turnkey solutions to their customers.

Master virtual commissioning in Visual Components

Connect a remote OPC UA server

Learn how to connect a remote OPC UA Server and PLC with a 3D simulation.

Geometry feature tools for component modeling

Learn how to use geometry feature tools to make the imported CAD models parametric.

Make a simple conveyor PLC ready

Learn how to model a conveyor and test it with sensors and PLCs.

Interested in our virtual commissioning solution?