Virtual Commissioning

Virtual Commissioning is the logical capability of validating an automation system’s PLC code, HMI logic, and electrical/mechanical design against a high-fidelity virtual model of the production line before the physical line is wired and energized. Siemens defines it as “the use of a virtual model that represents an accurate and realistic 3D simulation of mechanical, electrical and control systems in order to validate the physical functions of a production system prior to actual physical implementation.”

What it covers

• 3D plant simulation of the line, robots, conveyors, and human operators.
• PLC software-in-the-loop (SIL) and hardware-in-the-loop (HIL) testing with real or simulated controllers.
• Cycle-time, interlock, and safety-logic validation before steel hits the floor.
• Operator training on the virtual line in advance of go-live.
• Brownfield retrofit verification — model an existing line, test changes virtually before scheduled downtime.

Why it matters

Physical commissioning is the riskiest phase of new line installation: time on the floor is expensive, errors block production launch, and safety incidents are likeliest during shakeout. Virtual commissioning shifts a large fraction of the debug effort left, into engineering, where defects are cheap to fix.

Relationships (see sidebar)

• Part of Digital Manufacturing.
• Depends on Process Simulation and MES for the line and routing model.
• Supports CAM Manufacturing Planning, Manufacturing Execution, and Prototyping and Validation.
• Implemented by Tecnomatix Process Simulate (the canonical industrial product) and DELMIA.