The simulation and testing of manufacturing systems in a virtual environment before physical implementation, using digital twins and real-time simulation to validate control algorithms, robot motion, and process sequences, reducing commissioning time and costs during development.
Semantic Classification
Content
Overview
- Virtual commissioning (VC) evaluates control algorithms on simulation models that replicate actual plant dynamics, saving significant time and cost during development. Automotive OEMs, integrators, and line builders lead in using digital twins for production and virtual commissioning, with many manufacturers standardizing on tools like Siemens Tecnomatix Process Simulate for digital twin operations.
Technical Details
Implementation Methods
- Software in the Loop (SiL): Control hardware emulated with simulated process, no physical hardware required
- Hardware in the Loop (HiL): Real control hardware linked to real-time simulation of virtual devices
- Hybrid Commissioning (HC): Reality in the loop combining physical and virtual components
Key Capabilities
- PLC code validation and testing
- Robot motion and logic verification
- Mechatronic component simulation (clamps, conveyors)
- Collision-free robotic motion planning
- Offline programming and sequence validation
Leading Platforms
- Siemens Tecnomatix Process Simulate
- Siemens TIA Portal with Step7
- Nvidia Omniverse for digital twins
- MATLAB/Simulink integration
Applications
- Automotive assembly line validation
- Industrial robot cell commissioning
- Factory layout planning and optimization
- Control system error detection
- Industry 4.0 smart manufacturing development