Virtual commissioning and digital twins for innovative mechanical engineering.
The fast and easy solution for systems that really work.
Virtual commissioning
NEXT-LEVEL ENGINEERING. Facts & figures – learn more now
From virtual commissioning to actual commissioning
Virtual commissioning
In systems and mechanical engineering, the time between first inquiry and delivery or acceptance date is becoming shorter and shorter. The process starts with initial discussions with the customer and requires first results to be delivered in a timely manner.
Thanks to the agile development of simulation software for PLC systems and event-based systems, virtual commissioning and the creation of a digital twin gives users a powerful tool that can be used to master the challenges they face.
Ready to digitize?
Virtual commissioning is the early testing of planned machines and systems with simulation software, the virtual system. This is later used to create a digital twin with real commissioning. Depending on the appearance of the simulation tool, static or dynamic commissioning is carried out. Programs optimized with the help of the mechatronic model can then be safely transferred to the real system or to the machine, plant or robot. With virtual commissioning, errors can be identified early on and thus be easily avoided in early development phases. This helps avoid costly and time-consuming improvements to the actual system.
Many advantages – but also limitations
Improved engineering
Virtual commissioning – benefits and limitations
Virtual commissioning and the digital twin especially benefit engineering, since specific customer requirements can be included and tested for feasibility as early as the design phase. Particularly complex connections between the different areas of the machines and systems can be taken into account in early engineering phases, and solutions can be tested in advance. This effectively reduces the risk of possible planning errors and optimizes the quality of the systems and machines. At the same time, virtual commissioning also makes it easier to integrate the machine or system into the real production environment while it is in operation.
Shorter project timelines
It goes without saying that engineers are still crucial. But virtual commissioning benefits companies by significantly reducing the amount spent travelling to customers. This is a huge advantage in a global field like systems and mechanical engineering. Actual commissioning often takes up about a quarter of the entire project time.
In cases when the system or the machine is to be integrated into an existing system, the benefits of virtual commissioning also include reduced downtimes during system changeover – something plant and mechanical engineers can use to their advantage during negotiations. Small and medium-sized companies in particular gain greater flexibility through virtual commissioning and are thus able to better position themselves to compete with large companies.
Easy retrofitting
One of the major benefits of virtual commissioning is that it can also be used for retrofitting and reconfiguring machines and systems. This requires a digital twin, the virtual counterpart to a real machine. The digital twin not only contains the current status, but also records any changes made, such as the replacement of a damaged sensor and the associated changes to the control software.
Faster completion
The time needed for commissioning can also be significantly reduced with virtual commissioning. When combined with 3D simulation and simulation software, this is a decisive factor for keeping development and production costs as low as possible in plant construction. In the individual development phases, common additional expenses can be reduced to a minimum.
Early error detection
What are the other benefits of virtual commissioning?
Virtual commissioning especially benefits engineering, since specific customer requirements can be tested as early as the design phase. Particularly complex connections between the different areas of the machines and systems can be taken into account in early engineering phases, and solutions can be tested in advance. This effectively reduces the risk of possible planning errors and optimizes the quality of the systems and machines. Virtual commissioning also makes it easier to integrate the machine into the real production environment, providing users with a significant advantage.
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Take full advantage of what virtual commissioning has to offer
Virtual commissioning especially benefits engineering, since specific customer requirements can be tested as early as the design phase. Particularly complex connections between the different areas of the machines and systems can be taken into account in early engineering phases, and solutions can be tested in advance. This effectively reduces the risk of possible planning errors and optimizes the quality of the systems and machines. Virtual commissioning also makes it easier to integrate the machine into the real production environment, providing users with a significant advantage.
Sounds perfect for me
A few FACTS
- Reduce costs by up to 75%
- Increase productivity
- Improve quality
- Better adherence to deadlines
- Higher employee satisfaction
Virtual commissioning – applications in many industries
A simulation solution for many areas
Virtual commissioning of systems and machines is a great advantage in production – provided it is carried out well and that a few other requirements are met.
The benefits of virtual commissioning are clear: commissioning and development times are shortened and efficiency and quality in production are substantially increased.
Virtual commissioning is recommended when a machine has especially complex processes or the time window for commissioning the actual system is especially short.
Another benefit of virtual commissioning is in early virtual testing of a machine and making modifications. Virtual commissioning reduces downtimes when upgrading existing systems, leading to greater planning security.
The results: cost savings, shortened programming and planning times, a reduced risk of errors, and optimized quality of machines and systems.
How it works
Learn more about how our customers from various industries use iPhysics in their company and the results they have achieved.
Your road map for the
future
– optimized
in just a few steps
Get your company ready for the future – the right simulation links all areas of engineering.
Create your CAD model, no matter whether you use Creo, Inventor, IronCAD, Solid Edge or SolidWorks.
Transfer the CAD model to iPhysics at the touch of a button and create a simulation model.
Connect real controllers (PLC and robots) to the model.
See how mechanics and software interact directly on your screen.
Where could collisions occur? Benefit from the two-way CAD interface and fix errors in no time at all.
Run through different scenarios and find the ideal version.
Quick and easy!
Use your digital twin at the same time as production and monitor the system in operation.
Use the digital twin for predictive and remote maintenance to keep machine downtime as short as possible.
Impress your customers. Use your digital twin for sales, at trade fairs with AR or VR, or for training.
Virtual commissioning and digital twin –
perfectly positioned for the future
iPhysics supports a machine from the initial idea, planning and virtual commissioning, to its operation and maintenance.
I’m interested in a roadmap
These customers already simulate with us
Schedule a free consultation with our experts now. Learn how your company can achieve better planning and greater efficiency with virtual commissioning.
The result – better planning and greater efficiency
Virtual commissioning – for better planning and greater efficiency
Classic commissioning of mechatronic machines and systems can lead to very high costs and effort if the machines do not work as intended right from the start – and experience has shown that they rarely do. Unfulfilled specifications and unmet deadlines carry the risk of disputes with the customer that could lead to expensive modifications down the road, and even contractual penalties. But it doesn’t have to be this way.
Thanks to virtual commissioning using simulation software, many of these risks can be avoided in advance, saving time and money. Suitable solutions for simulation and visualization can significantly reduce costs for commissioning while at the same time ensuring and increasing the quality of mechanical components, electronics and electrical systems in advance.
Virtual commissioning & digital twins
What is a digital twin?
A digital twin is the virtual counterpart of a real machine that is created during virtual commissioning and brought to life during actual commissioning. All data from the real machine are available digitally in real time. This makes it much easier to monitor, modify and enhance the machine or system.
Digital twins will become increasingly important in research and development in the coming years. It is becoming clear that a digital twin is not a monolithic model of data, but rather various aspects of digital functionalities, representations, interfaces and models. This all leads to a sustainable increase in efficiency.
Why virtual commissioning with a digital twin?
Virtual commissioning with a digital twin offers a number of advantages, with time and cost savings especially worth noting. Programming a digital system simulation may be associated with high cost, but this is quickly recovered by the savings during subsequent real commissioning.
Modifying an industrial system once it has been commissioned and assembled requires a great deal of time and effort. Virtual commissioning and a digital twin help to avoid those costs in advance. When initial simulation models are created during the design and planning phase, possible vulnerabilities and potential for optimization can be identified and considered early on.
Digital twins in PLC programming
The virtual model of a machine created with simulation software can be linked to the virtual or real controller. When data is exchanged, the sensor data is written to the controller. Output signals are read and assigned to the objects on the surface, allowing the PLC programmer to check the functionality of the control program almost completely without needing the actual system.
Virtual commissioning with iPhysics
More than just a model for the future
Get your company fit for the future.
Our experts are happy to consult and help create your plan for the future. Schedule your free initial consultation today.
Trial workshop
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