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Service 04 · Digital twin

See it work before it's built.

Imagine catching every glitch, collision and programming error before your system ever touches the shop floor. That's the power of virtual commissioning — a digital twin of your automation system that lets us test, refine and perfect everything in a risk-free virtual world.

Explore Virtual Commissioning How it works
The problem

Debugging on a live line is the most expensive place to do it.

Traditional commissioning discovers logic faults with the machine in front of you, the customer watching, and a production window closing. Every fix costs downtime, travel and credibility.

On overseas installations the arithmetic is worse still: a problem that takes two hours to fix can take two days to reach.

40%
Typical reduction in onsite time
0
Collisions discovered on real hardware

Less unexpected downtime, a faster startup, and a system that behaves on day one the way it did in simulation.

A digital twin simulation of a production cell running on screen next to the physical equipment it models.
How it works

The real code, against a simulated machine.

A digital twin is not an animation. It is a physics- and signal-accurate model of your equipment, connected to the same PLC and robot programs that will ship.

Virtual commissioning loop The real PLC and robot programs exchange I/O signals with a simulated machine model, so faults are found and corrected in software before physical installation. REAL CONTROL SOFTWARE PLC PROGRAM (IEC 61131-3) ROBOT PROGRAM HMI / SCADA SCREENS SAFETY LOGIC SIMULATED MACHINE KINEMATICS & GEOMETRY SENSOR & ACTUATOR MODELS PART FLOW & TIMING COLLISION VOLUMES SIGNAL EXCHANGE I/O · OPC UA · EMULATION FAULTS FOUND HERE COST MINUTES. THE SAME FAULTS FOUND ON SITE COST SHIFTS.
What it catches

The faults that
normally reach site.

Every one of these is routine to find in simulation and painful to find on a running machine.

Collisions & reach limits

Robot paths that clash with fixtures, guarding or each other — including during fault-recovery moves nobody normally simulates.

Sequence & interlock errors

Deadlocks, missed handshakes and states the sequence cannot recover from without a power cycle.

Cycle time shortfalls

Discover the cell is 1.8 seconds over takt while it is still cheap to change the mechanical concept.

I/O mapping mistakes

Wrong addresses, inverted signals and missing feedback found before anyone is on a ladder with a meter.

Alarm & diagnostic gaps

Faults that stop the machine without telling the operator anything useful about why.

Operator flow problems

HMI sequences that are logical to an engineer and confusing to the person actually running the shift.

Benefits

Why it pays for itself.

  • Less onsite commissioning time, since faults are found and fixed in simulation first
  • Lower travel and accommodation cost on overseas installations
  • Shorter production shutdown windows for brownfield work
  • Operator training can begin before the machine is delivered
  • Cycle time verified against takt while changes are still cheap
  • Safety sequences rehearsed without exposing anyone to a real hazard
  • A reusable model for future product variants and line changes
Best for

Overseas installations where onsite time is expensive

Best for

Tight shutdown windows in existing plants

Best for

Multi-robot cells with complex interaction

Best for

High-mix lines with frequent changeover

Related

Often delivered together with

Service 02

Controls software development

Virtual commissioning validates the same code we write — not a simplified stand-in.

 Service 03

Turnkey automation

Included as standard on complex multi-robot cells we design and build.

 Service 08

Onsite commissioning

Arrive on site to install and prove a system that has already been debugged.

Looking for something else?

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The future of automation, today.

If your next installation is overseas or inside a shutdown window, this is the conversation to have first.

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