How does a digital twin help me to secure complex production systems with virtual commissioning? Virtual commissioning significantly reduces downtimes and project life spans.

The commissioning of new production lines is - not lastly due to increasing complexity in production - very time-consuming and is also possible after complete assembly of the line. If an existing line is retrofitted to a new product, a production stop is required for the commissioning.

Virtual Commissioning

Virtual commissioning can significantly shorten the down times and/or the project life spans. For this purpose, the line is constructed as a "digital twin" and all functions are defined, tested and safeguarded in this virtual model. Unlike traditional simulation, the virtual model is connected to the real control system and reacts identically to the real line with integrated behavior models. This enables safe simulation and optimization of robot programs on the computer and the validation of the system control unit (PLC program simulation). Without virtual commissioning, the PLC validation would only be possible after construction of the real line and any programming errors could result in expensive collisions and repairs.

Then the programs optimized with the help of this mechatronic model are transferred to the real system. The result is greater operational safety with improved software quality of the PLC and the robot program right from the start.

Virtual Commissioning

Scalable solution based on a digital twin

CENIT's FASTSUITE Edition 2 offers a scalable simulation solution for this problem, which is based entirely on the concept of the digital twin. The robot programs and plant models created and simulated with FASTSUITE Edition 2 should be applicable directly for PLC validation or virtual commissioning of the plant. A standardized interface is available for connection of external control systems with OPC-UA. Realtime integration via a field bus system is also provided.

In summary: With the virtual commissioning of the plant control system on the basis of a digital twin of the plant, errors are covered at an early stage and already eliminated during the development phase. In this manner, expensive costs for change or finishing work on the real system can be avoided ahead of time. In addition, due to the close intermeshing of mechanical design, control system development and electrical design, parallel work and close collaboration can take place in early project phases. Therefore, a company achieves a significant reduction in risks, errors and later downtimes.

Virtual Commissioning
Virtual Commissioning