Detect Early, Resolve Fast, and Enhance Efficiency with Visual Components

Accelerated Project Timelines

Visual Components speeds up design-to-deployment, identifying and fixing 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

Visual Components promotes efficient collaboration, enabling synchronized development and testing, which streamlines 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), streamlining the commissioning phase and changing the conventional sequence of events.

Virtual Commissioning: 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, 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

1. 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.

2. 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.

3. Control Integration

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

4. Simulation and Testing

Conduct comprehensive simulations and testing, covering both regular operations and potential exceptional scenarios to verify system functionality.

5. Iterative Refinement and Safety Checks

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

6. 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.

7. Documentation and Future Reference

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

How Are Our Customers Using Visual Components for Virtual Commissioning?

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Learn Virtual Commissioning with Visual Components


See for yourself how Visual Components 3D manufacturing simulation solutions can help you save time, reduce costs, and improve production performance!