Virtual commissioning is an important part of Industrie 4.0. It is used to import and test planning data on a virtual machine, the so-called "digital twin", before it is transferred to the real machine. The following article explains how to use this amazing technology to detect errors and reduce costs in the early development phases.
In order to explain how virtual commissioning works, a distinction is first made between it and the classic form or so-called real commissioning. In this case, the developed software functions are tested and optimized on the real machine or plant. During this process, various function and performance tests are carried out as well as simulations of safety scenarios and critical states.
The real commissioning can only be carried out after the machine has been completed. This extends the time that elapses before the machine can be handed over to the customer. In addition, this procedure involves various risks. For example, damage to the machine or unplanned revisions to the software can occur.
With virtual commissioning, on the other hand, importing and testing takes place on a computer or a virtual machine, which is also referred to as a "digital twin". Only then are the programs optimized on this model transferred to the real plant or machine. Virtual planning enables errors to be detected and eliminated in the early stages of development. This avoids the additional work and costs that would be incurred if the programs were used directly on the real system.
Special software is used to create an image of the machine to be developed for virtual commissioning. In the process, all mechanical and electrical properties of the system are simulated virtually and realistically – and a 3D simulation of the future real machine is obtained that behaves exactly like it. Most virtual commissioning software offers support in this process by providing typical parts and components. Many suppliers also offer ready-made virtual twins of their components that can be easily integrated into the simulation.
The aim of virtual commissioning is therefore to map the complete machine system virtually. Not only individual machines or systems such as robots can be mapped, but even entire factories. The digital twin – i.e. the model of the machine or system – behaves exactly like the real machine and its individual components. It can therefore simulate all behaviors over the entire life cycle of the machine in real time. In addition, the digital twin includes all the information of the real machine – for example, on development, operation, maintenance and disposal.
Subsequently, the computer on which the simulation was created is connected to the control program of the real machine. As a result, the virtual model in the software shows 1:1 identical reactions to the future real machine. The virtual model can now be programmed if desired. In this way, functions for machine control and their mechanical behavior can be simulated and tested on the virtual model.
Especially in the production of machines and plants, virtual commissioning has a high benefit. The prerequisite is that the procedure is used correctly. If implemented correctly, virtual commissioning shortens the time required for development and commissioning. The result is a significant increase in efficiency in production.
The use of virtual commissioning is particularly recommended if the machine is very complex or if expensive materials would be required for testing the real machine. Even if the time available for commissioning the real machine is limited, virtual commissioning is worthwhile. In addition, virtual commissioning can shorten downtimes when rebuilding existing plants. Ultimately, this leads to greater planning reliability.
The areas of application for virtual commissioning are diverse. The process is primarily used in the context of automation in industrial manufacturing, i.e. in industries such as mechanical and plant engineering, the automotive industry and logistics. Here, digital twins are used in the development of mechanical and electrical machines and plants, as well as in software development.
Digital twins prove particularly helpful in the following areas:
It is true that the effort for generating the virtual model is quite high at the beginning. However, this investment is worthwhile in view of the potential costs that could arise from software or design errors as well as damage during real commissioning. In addition, the quality and efficiency of the entire software development increases.
The virtual commissioning and Control Network offers numerous advantages for the development of control software for complex machines and plants. For example, the software can be developed at an early stage of design and completely independently of the future machine. This results in a very short time-to-market and thus enormous time and cost savings.
All functions of the control software – including the simulation of critical states – can be tested on the digital twin. This avoids risks such as damage to the real machine and also increases software quality. In addition, critical tests that cannot be carried out on the real machine due to high costs or risks can also be carried out without any problems. In addition, the training of machine operators is much easier with the simulation software. Commissioning is also carried out extremely comfortably in the office instead of in the noisy workshop or factory floor.
Another advantage is the location-independent development and further development of the control software. This makes it possible to carry out simulations and tests on site at the customer’s premises, but also in the company’s own factory. The machine system can thus be further developed – without any travel costs – and error analysis can also be carried out "remotely" without any problems. This not only avoids machine downtimes at the customer’s site, but also opens up the possibility of offering the customer innovative services such as function enhancements.
Despite all these advantages, experts widely agree that virtual commissioning will never be able to completely replace the real thing. This is because the virtual commissioning system cannot, of course, detect assembly errors such as improper wiring or defective construction or industrial spare parts on the real machine.
In addition, the virtual commissioning always moves only within the limits of the virtual model. If there are errors or inaccuracies in this model, the simulation is also inadequate. To prevent such errors from occurring in the first place, only specialists with experience in using the tool and the necessary care should be used to create the simulation model.
Especially in the development of complex machines and plants, virtual commissioning has become irreplaceable. Manufacturers who use virtual commissioning have a decisive competitive advantage over companies that still rely exclusively on conventional commissioning.
If one thinks further about the possibilities of virtual commissioning, simulation models enable an even more agile way of working throughout the entire development process. Thus, software development as well as mechanical and electronic design can map, test and optimize their development statuses in parallel in one and the same digital twin. In addition, there is potential for sales, which can use the visualizations and performance tests for customer communication.
