Why Physics Makes the Difference
Visualizing machines and systems using physics-based simulation ensures that machine behavior is calculated based on real physical laws. The primary focus is not on perfect processes or predefined behavior, but on the true physical properties of the system, such as masses, forces, friction, energy flows, and their interactions.
Only when physical quantities are accurately represented does the simulation model behave not simply as it was “programmed,” but as it would actually behave under real-world conditions. And that’s precisely the difference: Only then can truly reliable statements be made in engineering.
Physics-based simulation is now a prerequisite for the successful implementation of virtual commissioning, digital twins, or virtual engineering.
Physics as the Foundation of Simulation
Image of a laptop with an iPhysics simulation of a wood cutting machine
In traditional simulation environments, processes are often modeled logically or using signals. States are changed, signals are set, and sequences are executed. This works well for testing control concepts or process logics – but it only represents reality in a highly simplified way.
In contrast, physics-based simulations go a step further. Here, motion arises from forces, dynamics from inertia, and stability from real couplings between multiple components.
When an axis is accelerated in the simulation model, real moments of inertia come into play. Or when a gripper picks up a workpiece, the mass and center of gravity influence its behavior. When multiple systems are coupled simultaneously, real feedback loops occur.
This approach enables the realistic representation of dynamic effects, such as the analysis of limit and failure cases, traceable cause-and-effect relationships, and reliable statements about a machine’s performance.
The simulation thus becomes a true representation of the system and not just an abstract animation.
Physics at the heart of iPhysics
With iPhysics, machineering pursues precisely this physical approach. The simulation platform not only provides individual functions but also a physically sound system model that can be used across all disciplines.
Mechanics, drive technology, sensors, and control logic are not considered in isolation but are integrated within a common physical model. This results in a comprehensive understanding of machine behavior, from the concept phase to virtual commissioning.
With this approach, physically consistent multibody simulation, coupling with real control software, integration into existing engineering processes, and the reusability of models across project boundaries are possible.
iPhysics thus functions not only as a simple simulation tool but as the technical foundation for all digital development processes.
Foundation for Digital Twins and Virtual Commissioning
It is important to understand that a digital twin only demonstrates its full potential when it can not only describe but also make real predictions. Simple geometric models or state-based representations are far from sufficient for this. Only with physics-based models do digital twins become computable.
For virtual commissioning, this means that the control software is tested against a physically realistic plant model. Movements are performed with real accelerations, real loads can influence system behavior, and feedback loops are generated automatically. This makes errors visible long before the hardware is even built.
Companies benefit from this because it reduces commissioning risks, shortens start-up times, improves planning, and increases quality.
Physics-based simulation allows many insights to be gained in early development phases. This makes changes not only easy to implement but also less costly.
Why physics is crucial in today’s simulation: Modern machines are becoming increasingly complex. Increased product variety, ever-shorter product cycles, and the associated higher energy efficiency requirements necessitate new development strategies. Fortunately, the costs of errors are shifting increasingly toward earlier project phases.
Only physics-based simulation provides a stable foundation here. It creates the necessary transparency in system behavior, reduces uncertainty, and enables well-founded decisions based on explainable models.
Why physics is crucial in today's
Modern machines are becoming increasingly complex. Increased product variety, ever-shorter product cycles, and the associated higher energy efficiency requirements necessitate new development strategies. Fortunately, the costs associated with errors are shifting increasingly toward earlier project phases.
Only physics-based simulation provides a stable foundation in this context. It creates the necessary transparency in system behavior, reduces uncertainty, and enables well-founded decisions based on explainable models.
machineering customers benefit from this because virtual commissioning and digital twins are not seen as isolated applications, but as integral components of a comprehensive, physics-based engineering approach. iPhysics is the ideal platform for this, simultaneously connecting design, automation, and operation.
Physics-based simulation is not an optional add-on module, but rather the most important method in modern machine development. It replaces simple assumptions with calculable relationships and creates a deep, comprehensible understanding of the system.
The iPhysics simulation platform has long utilized the physics-based approach, thus ensuring the successful implementation of virtual engineering.
Want to know more? Request our trend paper now!
Links to the website
General link:
Learn more about iPhysics and our virtual commissioning solutions on our website: www.machineering.com.
Directly to the product page:
Discover iPhysics – your solution for cloud-based simulation: www.machineering.com/en/products/iphysics
Contact page:
Do you have any questions? Contact us for more information: www.machineering.com/en/contact
Overview of VIBN:
Find out more about virtual commissioning and its benefits here www.machineering.com/en/virtual-commissioning
