Virtual commissioning in the engineering process
Virtual commissioning is a common engineering method used today in which the real-world control system of a machine is tested on a digital twin long before the physical machine is even built. The goal of virtual commissioning is to validate the machine’s functional behavior early on and to identify and prevent errors during development, before they are discovered during actual commissioning.
Virtual commissioning is used in mechanical engineering to shorten development times, minimize risks, and make complex automation systems manageable. It combines simulation, automation, and software testing into a seamless process.
Virtual commissioning as a functional test of the control software
Virtual commissioning doesn’t just mean visualizing a machine; it means thoroughly testing the actual control software under realistic conditions in all areas. The PLC and robot programs are used as they would be under real-world conditions and coupled with a virtual machine model.
The controller communicates with the digital twin via real or emulated inputs and outputs. For the controller, the digital twin behaves exactly like the real machine. Sensors provide the relevant data, and movements follow physical laws.
Virtual commissioning is therefore a system test that verifies early on whether the machine actually functions correctly in conjunction with all its components.
Typical applications of virtual commissioning
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PLC programming and testing
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Robot programming
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Safety functions
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Cycle time and process validation
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Material flow of linked lines and systems
Distinction from classical simulation
Traditional simulations in mechanical engineering are often used to design individual aspects, such as mechanics, kinematics, or cycle time. These simulations often operate without real control software and consider subsystems in isolation.
Virtual commissioning, on the other hand, takes a different approach: It considers the entire system, including the machine and its controller. The real controller thus becomes part of the test. This is a logical consequence when one considers that the behavior of the real machine will later result from the interaction between the controller and the physical model.
While traditional simulations merely evaluate concepts, virtual commissioning validates the actual behavior of the finished machine. This allows for the early detection and prevention of errors that would otherwise only become apparent through the interplay of multiple disciplines.
Virtual commissioning with iPhysics
A suitable technical foundation is required for the consistent and sustainable implementation of virtual commissioning. iPhysics is an engineering platform that enables virtual commissioning based on physics-based digital twins.
iPhysics is a platform that maps machines as physical models, directly links the control software to these models, and thus supports virtual commissioning as part of a seamless engineering process.
During virtual commissioning, the iPhysics model acts as virtual hardware for the control system. This allows for the systematic testing of real-world effects such as delays, edge cases, or error situations.
A key feature of iPhysics is the reusability of the digital twin. The same model used for virtual commissioning can later be used for software testing, cycle time optimization, training, or modifications. Virtual commissioning thus becomes a permanent part of the machine lifecycle. It can even support the customer—the machine operator—during ongoing operations, for example, by commissioning new products on an existing system, and much more.
How does virtual commissioning work? - Practical experience
Benefits of virtual commissioning in mechanical engineering
Virtual commissioning reduces actual commissioning time because many errors are identified and thus avoided before the machine is even built. Furthermore, the control system interface is tested early on under realistic conditions.
In addition, virtual commissioning improves collaboration between mechanical, electrical, and automation engineering. All participating engineering disciplines can work in parallel, as software tests are no longer dependent on the hardware’s completion status.
Virtual commissioning therefore leads to lower commissioning risks, better-planned projects, and higher software quality.
Conclusion
This clearly demonstrates that virtual commissioning is an indispensable method in modern mechanical engineering for validating complex machines early in the process. It enables realistic testing of control software long before the actual hardware exists.
In conjunction with a platform like iPhysics, virtual commissioning transforms from a project-specific tool into a comprehensive engineering application.
This makes virtual commissioning the foundation for efficient, robust, and future-proof engineering.
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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:
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Overview of VIBN:
Find out more about virtual commissioning and its benefits here www.machineering.com/en/virtual-commissioning
