What is Virtual Commissioning?
Virtual Commissioning consists of reproducing a behaviour in a virtual environment through software simulation applied to the Digital Twin, which allows optimization before commissioning. The virtual model communicates with the real machine, becoming a true digital twin.
Through this system, it is possible to simulate the realization of a plant, visualizing the design before its actual implementation. This allows for real-time modifications and optimization of resources in terms of both cost and productivity.
Virtual Commissioning is gaining increasing importance in the Industry 4.0 vision due to its ability to perform early diagnostics, conduct tests in a virtual environment, and achieve 100% optimal results. This technology is particularly popular among companies in the manufacturing sector, which use highly automated machines and need to test the designed elements and their related automations (PLC, Motion Control, CNC) and Human-Machine Interfaces (HMI).
Current systems—machines, transfer lines, plants—are becoming more and more automated, often including sophisticated tools, robots, transfer lines, and other safety equipment, all controlled by programmable solutions like PLC, Motion Control, and CNC.
What are the advantages of Virtual Commissioning?
Virtual Commissioning offers several advantages:
- Reduces software development time, as debugging can be performed even before physical assembly.
- Analyses system efficiency, anticipating malfunctions that could affect machine performance in advance.
- Ensures system safety, by conducting tests on the efficiency of planned safety systems and improving the conditions under which employees operate the machinery.
- Provides after-sales support, as Virtual Commissioning allows for the real situation purchased by the customer to be recorded. In the case of future assistance, first-level checks can be carried out without additional costs.
- Reduces costs, thanks to the ability to virtually test a solution before its actual implementation.
How does Virtual Commissioning work?
Now, let’s delve into how Virtual Commissioning works.
To perform Virtual Commissioning, automation engineers begin with a 3D model that includes the physical components of the machine to be analysed. They define the kinematic constraints, considering factors like friction and physical conditions such as gravity, to accurately simulate reality within the virtual environment.
Next, they define the actuators, their operational sequences, and motion profiles. Finally, the I/O (Input/Output) signals are simulated by mapping them to the control system.
At this stage, all necessary tests can be conducted, and any automation programming errors can be corrected—exactly as they would in a real scenario but ahead of time, without the need to wait for machine production or assembly.
Virtual Commissioning can significantly reduce both downtime and overall project duration. To achieve this, a Digital Twin of the production line is created, where all features are defined, tested, and optimized in this virtual model.
