Instead of using the actual machine on-site at the plant operator’s facility, virtual commissioning can be implemented in a digital development environment in the office. Extensive tests during machine simulation make it possible to identify and eliminate design and function errors. This approach significantly speeds up the actual commissioning process.

Because virtual commissioning can be performed in parallel with engineering, the findings gained from the simulations and tests can also be used to improve engineering quality. Tests of the actual PLC program using virtual controllers increase the certainty that the control system will function as anticipated by the customer during actual commissioning.

Less time on site, reduced risk of errors, shorter commissioning time: Thanks to in-depth testing in advance, only minor corrections are expected during actual commissioning, which significantly decreases development costs. 

During virtual commissioning, everything can be tested risk-free and without the customer’s plant personnel. Extensive troubleshooting significantly reduces the risk of errors and even defects in the actual machine. 

You can use PLCSIM Advanced – the virtual controller for the SIMATIC S7-1500 controller – to simulate and validate the PLC code. The simulation includes communication, knowledge-protected function blocks, safety, and a web server. Support is also provided for multiple and distributed instances in order to simulate multiple controllers on a PC or in a network. A documented interface is provided for the data exchange.

With the NX Mechatronics Concept Designer, machine builders can simulate and test the mechanical components of their machines in a virtual environment. PLC programs and visualizations are simulated and validated with PLCSIM Advanced and the TIA Portal. Depending on the requirement level, the behavior of active components like drives and valves is mapped in another PLCSIM Advanced model or with the SIMIT simulation software. This combination supports both the preparation and a smooth commissioning. 

The virtual commissioning of robot cells or entire production lines takes place using TECNOMATIX Process Simulate and PLCSIM Advanced. OPC UA, the standardized communication protocol, is used to exchange data between robots, machines, and the plant to ensure that all processes, material flows, and similar activities can be simulated and optimized prior to the actual commissioning.