Virtual Commissioning & Digital Twin
Virtual commissioning using fe.screen-Sim reduces risks and time pressure during real commissioning.
Software, sequence and state logic are tested before system start-up.
Virtual Commissioning - Explained Briefly
Virtual commissioning enables the systematic validation of PLC programs, visualization and process logic before real commissioning takes place.
It is based on a digital twin that represents the functional behavior of the system and allows reproducible testing under controlled conditions.
Virtual commissioning is particularly beneficial for:
- complex systems with multiple operating states
- short commissioning windows or high time pressure during system start-up
- international installations or limited on-site availability
- increased requirements for software quality and process stability
- requirements for training, testing or future expansions based on a digital twin
Virtual Commissioning - Benefits
Virtual commissioning shifts key testing activities from real commissioning into the engineering phase, creating a reliable foundation for a stable system start-up.
Summarized briefly:
- Early detection of errors before the first real system run
- Reproducible testing of normal operation, fault conditions and limit scenarios
- More predictable commissioning through prepared and tested software
- Reduced on-site effort and less rework under time pressure
Virtual Commissioning - Why KV-Automotion
KV-Automotion implements virtual commissioning using fe.screen-Sim in a practical, application-oriented manner - with a focus on original PLC code, clear state models and structured test scenarios.
We combine PLC engineering, HMI/PCS expertise and commissioning experience into a reliable and testable overall system.
This is what defines our collaboration:
- Original PLC code in the final project state - without simplifications
- Structured test scenarios including limit and fault conditions
- Clear interfaces and transparent state models
- Experience gained from real commissioning projects (on-site and remote)
The Digital Twin as the Foundation
The digital twin represents the real system both functionally and logically. Control software, simulation and visualization operate together within a closed system environment.
Components of the digital twin:
- PLC program in the original project state
- Simulation model of the system
- Visualization and process control
The digital twin responds to control commands in the same way as the real system and provides defined feedback to the control system. This allows system states to be tested reproducibly, including limit and fault scenarios.
Importance of Virtual Commissioning
In traditional projects, many issues only arise when mechanics, electrical systems and software interact for the first time. Virtual commissioning shifts this critical phase into a controlled test environment.
Testing areas of virtual commissioning:
- Testing of complete sequence and state logic
- Verification of limit and fault scenarios
- Validation of safety and release concepts
- Analysis of process and cycle behavior
- Early coordination between mechanical design, software and operations
Virtual Commissioning in Practice
KV-Automotion implements virtual commissioning using fe.screen-Sim in combination with SIMATIC TIA Portal and SIMATIC Classic. The real or simulated PLC is coupled with the simulation model, allowing the original program to be tested against defined system feedback.
Implementation in practice:
- Coupling of the real or simulated PLC with the simulation model
- Testing of complete system sequences (normal operation, faults, limit cases)
- Verification of operator and process logic via HMI and PCS
- Systematic execution of defined test scenarios
- Testing of the final project software without simplifications
Process Flow: Traditional vs. Virtual Commissioning
The following illustration shows in simplified form how the project workflow shifts through the use of virtual testing. As a result, real system start-up becomes more predictable, since debugging and integration tasks are already addressed during the engineering phase.
Traditional Project Workflow
- Engineering (PLC/HMI/PCS)
- Assembly / wiring / integration
- Real commissioning + debugging under time pressure
- Acceptance / production start
Project Workflow with Virtual Commissioning
- Engineering (PLC/HMI/PCS)
- Virtual testing on the digital twin (scenarios, limit cases, faults) is carried out independently of assembly, wiring and integration of the real system and can, depending on the project, be performed in parallel with or prior to the implementation phase.
- Real commissioning (focus: fine-tuning, process optimization)
- Acceptance / production start
Project Execution: Traditional vs. Virtual Commissioning Compared
Virtual commissioning does not change the tasks within a project, but rather the timing of when they are performed. Critical testing activities are shifted from real commissioning into the engineering phase.
| PLC Programming | |
|---|---|
| traditional | XSoftware is developed based on specifications and assumptions |
| VC | ✓Software is tested in parallel on the digital twin |
| Error Detection | |
| traditional | XErrors only appear during the first real system run |
| VC | ✓Errors are detected already during the engineering phase |
| Sequence and State Logic | |
| traditional | XValidation takes place under time pressure during commissioning |
| VC | ✓All operating states can be tested systematically in advance |
| Fault and Error Scenarios | |
| traditional | XOnly limited testing possible |
| VC | ✓Can be tested in a targeted and reproducible manner |
| Interfaces (PLC / HMI / PCS) | |
| traditional | XIssues only become visible during system interaction |
| VC | ✓Interfaces are validated at an early stage |
| Visualization & Operating Logic | |
| traditional | XAdjustments are made during commissioning |
| VC | ✓Operating concepts are tested before system start-up |
| Commissioning Phase | |
| traditional | XSoftware adjustments and testing take place in parallel |
| VC | ✓Focus on fine-tuning and process optimization |
| Planning Reliability | |
| traditional | XDependent on real system progress |
| VC | ✓Improved scheduling and resource planning |
| Downtime | |
| traditional | XPossible downtime due to software adjustments |
| VC | ✓Reduced downtime through prepared software |
| Software Quality | |
| traditional | XStrongly dependent on on-site time pressure |
| VC | ✓Systematically tested and documented |
| Changes & Optimization | |
| traditional | XRisk due to testing on the real system |
| VC | ✓Testing on the digital twin without production risk |
| Documentation | |
| traditional | XOften created afterwards |
| VC | ✓Test scenarios are created in parallel with engineering |
| Long-Term Benefit | |
| traditional | XProject completion without a simulation basis |
| VC | ✓Digital twin usable for extensions and training |
Use Beyond Commissioning
The digital twin does not end with system start-up. It can be used as an engineering and operational tool throughout the entire system lifecycle.
Possible applications after commissioning:
- Software modifications and extensions
- Retrofit and modernization projects
- Training of operators and service personnel
- Analysis of faults and process optimization
Integration into Existing Projects
Virtual commissioning can be applied as an integral part of a new project or selectively for critical system sections, depending on the project requirements. Scope and test scenarios are integrated into existing engineering processes.
Typical integration scenarios:
- As an integral part of a new project
- For targeted validation of critical system sections
- For quality assurance of existing software
Our Technical Approach
We consider virtual commissioning an engineering tool for the technical validation of automation projects. The objective is to verify functions, sequences and system interactions at an early stage in a transparent and traceable manner, creating a stable foundation for commissioning and subsequent system operation.
Principles of our approach in virtual commissioning:
- Realistic digital twins
- Original PLC code without simplifications
- Structured and reproducible testing
- Measurable added value for commissioning and operation
Planning an Automation Project?
Talk to us about your requirements. We support you from software development through to successful system handover.