Virtual commissioning in five industries
Five industries, five names for the same day: the first time the control system is tested, on a machine that is already built. We arrive with the PLC code, the robots and the safety logic already validated against the line's digital twin.
Controls are the last thing tested.
In any plant, the control system is integrated last and questioned first. Until then, PLC code, robot paths and safety logic are tested apart. Their first joint test happens on the real machine, against a date that no longer moves. Each industry names that day differently. Underneath, the problem is the same: nobody has seen the controls with the line full.
Five different plants. The same control layer.
- Automotive Body shop, paint shop, final assembly and EV retooling.
- Aerospace Drilling and fastening, aerostructure assembly, moving line and tooling.
- Logistics AS/RS cranes, sortation, conveyors, AGVs and palletising.
- Food & Beverage Filling, packaging, end of line and format changeover.
- Pharmaceutical Aseptic fill-finish, line clearance, changeover and serialisation.
Our layer is the controls. Our record is automotive.
The control layer is ours end to end: PLC code, robot programs, machine safety and the electrical engineering from schematic to CE mark, all proven against the line's twin before the line exists. Not ours: the tooling, the line itself, the systems above the PLC. The record was earned in automotive: ten OEM programmes, 400+ validated PLC architectures, 1,000+ robots programmed. The other four industries get the method.
The method does not change from one industry to the next.
- Phase 01
The twin of the line
The machine or the cell is modelled from the mechanical design, with its axes, sensors and actuators, until it behaves the way it will behave on the floor.
- Phase 02
Your code, not a mock-up
The real PLC code and the real robot programs are connected to the model. What gets validated is the software that will ship to the installation, not a demonstration build.
- Phase 03
The full sequences
Start-up, stopping under load, product change, fault and state recovery. They run end to end against the twin, which is where the faults that only appear on a full line show up.
- Phase 04
Commissioning on site
We arrive with the code already proven. Time on site goes into tuning, not into discovery.