Commissioning is probably the most exciting moment in the development of a new machine. Does the entire system work? Do the mechanical, electrical, and control software components interact properly? Have all movements been tested and process flows validated? In practice, however, it is precisely at this point that small—and even larger—errors tend to surface. Consequently, especially during the initial tests on the actual system, unexpected system reactions, last-minute software adjustments, or suboptimal motion profiles often occur.
This is because modern machines have become significantly more complex compared to the past, the proportion of software is continuously increasing, and many engineering disciplines work in parallel over long periods. As a result, a large part of the validation is shifted to the late project phase.
The Increasing Complexity of Modern Machines
Machines today are highly complex systems. Not only the mechanical structure, but also the drive technology, sensor systems, safety functions, and control software play a central role. These components all influence one another; even the smallest change to a motion profile can therefore affect sensor responses, safety logic, or cycle times. These interdependencies are not always apparent during development. They only become apparent during actual commissioning. All components are operated together for the first time, revealing the system’s actual behavior.
One reason for this trend is the steadily growing proportion of control software. Most motion sequences, synchronizations, or safety functions are now implemented in software. The combination of the physical machine and the control software influences dynamic effects, sensor delays, or communication latencies. Since these effects can only be tested to a limited extent without a realistic environment, these issues only become apparent when the software and the physical machine are brought together for the first time.
Integration often happens late
In many projects, mechanical design, electrical design, and automation work in parallel for a long time, with each discipline initially optimizing its own area. The actual integration of the results often does not take place until shortly before commissioning. New machines are frequently not fully tested until they are on-site. This is where physical dynamics, control logic, sensor technology, and process flows come together for the first time, and mechanical motion models, electrical signals, and control logic are combined. If the disciplines do not fully align, problems arise. These must then be resolved promptly.
Commissioning thus becomes a phase of integration, testing, and optimization. Fault analysis takes place directly on the actual system, while changes to software or parameters are made in parallel. Under these conditions, it is difficult to investigate complex interrelationships.
Virtual commissioning as an approach to risk reduction
To avoid such situations, more and more companies are turning to virtual commissioning. This involves continuously modeling the machine’s behavior in a simulation environment during the development phase.
A virtual model of the machine is linked to the actual control software. This allows motion sequences, sensor logic, and error scenarios to be thoroughly tested long before the actual system is available. This makes problems visible earlier and allows them to be avoided during the development phase.
The increasing susceptibility to errors in modern commissioning is primarily a result of growing system complexity and the late integration of the disciplines involved. When the first complete system test is not performed until the actual machine is in place, errors are inevitable.
Virtual commissioning shifts a significant portion of these tests to an earlier project phase. As a result, the actual commissioning becomes less of an experiment full of surprises and more of a predictable step in an already validated development process.
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