Virtual Commissioning

Simply put, virtual commissioning uses "virtual" simulation technology to "commission" – design, install, or test – control software with a virtual machine model before connecting it to a natural system.

Although commissioning is integral to any process, it usually occurs late in development. And while it only accounts for 25% of development time, it is at this stage that most delays occur. It is estimated that up to 70% of delays result from control software errors. Therefore, the purpose of using a virtual startup is to allow early validation of machine code. This dramatically reduces the risk of deploying a buggy application. The most time-consuming aspect of getting up and running is software implementation or software redesign. Hence, a virtual startup enables higher quality software and shortens the overall startup time.

Since its inception, the intent of operating in a virtual environment has been to help solve problems that arise when assembling manufacturing systems to integrate and work with a PLC. The automation industry has long recognized the potential benefits of using virtual models to simulate the operation of physical systems. But to be successful, the virtual factory model must be an accurate representation of the intended design. While these models were important in the aerospace and automotive industries, their implementation previously lacked automation. To achieve performance, companies needed plant models that integrated with their PLC design methods, which were unavailable through early standards.

 

The evolution of virtual commissioning

Virtual commissioning was envisioned almost 20 years ago as a promising technique to aid machine development. However, hardware capabilities do not make PLC testing cost-effective, especially with real-time simulation requirements when using hardware PLCs. But technology does not stand still. In 2006, Zäh et al. showed that virtual commissioning could save up to 75% of the time required for commissioning.

Many technological barriers have been overcome to realize the benefits of model-based system integration. The current state of technology offers practical techniques that are more accessible to the automation industry than ever before. As part of the growing need to accelerate development and minimize risk in developing new and innovative products, digital twins and virtual commissioning techniques are fast becoming essential technologies. But how exactly does a virtual launch work?

 

How it works

You're probably familiar with the traditional setup, but let's go through this from the ground up. The difference between actual physical and virtual commissioning is that an actual commissioning process involves direct testing on a natural production system (i.e., a machine), an actual controller (i.e., PLC), and other necessary devices, including sensors and actuators. However, the virtual setup uses virtual copies of system components and has several configuration options.

 

Virtual Machine Dynamics setup is a combination of three important parts:

  1. A digital model (sometimes known as a digital twin)
  2. Controller code that governs motion and responds to sensor feedback
  3. A development environment that allows the two to run together.

 

For this to be practical for the manufacturing and automation industries, outside specialists must be adequate for use. The development of advanced, model-based design methods has evolved into a digital twin. In addition to the digital twin, the software standards for connecting the model have also significantly improved. Together, these technologies enable the practicality of virtual commissioning throughout the automation industry.

Organizations can use virtual commissioning techniques with the right tools for their machine design projects. They may use these techniques to reduce overall setup time, lower setup costs, or create a more reliable time to market for reputation purposes. While programs and specifications can vary, a typical virtual startup process has many commonalities.

 

Advantages of virtual commissioning

A significant advantage is that it brings the startup phase forward. Using virtual prototypes, manufacturers can test control software in parallel with other engineering steps. This dramatically reduces the risk of errors later in the development process.

Virtual setup also allows testing in a virtual environment. This deployment approach allows for improved software quality and increased safety for workers. It also reduces the risk of dangerous machinery when performing real-time tests. And that's just the beginning – setting up with a digital twin brings many more benefits.

 

Adopting new development techniques has become essential for success in the manufacturing and automation industries. As demands on product requirements increase, design risks create significant problems and threaten the success of those trying to keep pace. The virtual commissioning technique promises to reduce delays and costs associated with system integration and commissioning. While previously only possible by specialized professionals, powerful modeling tools and consistent information standards have paved the way for modern and accessible virtual commissioning solutions. Companies and research groups around the world have heavily invested in this technology, creating powerful techniques for model-based design. As these technologies develop, their role in the automation industry will continue to become an essential component of product design.