What is Virtual Commissioning?

Virtual Commissioning is a process that has revolutionized the industry, allowing to validate and start up an installation virtually, without the need for all the elements of the system to be physically assembled.

Virtual Commissioning simulates the operation of automated control systems, machinery and industrial processes before their physical implementation in the real environment, allowing to check if they work correctly or, on the contrary, if there are any problems that need to be fixed before their final start-up, which translates into significant time and cost savings.

Virtual Commissioning allows companies to reduce start-up costs, time to market and project costs by up to 25%.

In essence, it consists of using virtual models of systems and processes to perform exhaustive tests and optimize their operation before carrying them out in the real world, taking advantage of 3D modeling and simulation technology to create accurate digital replicas, which will allow them to validate the behavior of the systems in different situations, without compromising the integrity of the physical equipment or interrupting production.

Virtual Commissioning main advantages

Reduces the time to market of the final product

With Virtual Commissioning, companies can accelerate the process of developing and bringing their final products to market. By simulating and testing systems virtually before physical implementation, development times are reduced and the product reaches the market faster.

Reduces the time, risk and costs of actual project startup

By identifying and resolving potential problems during the simulation stage, the risks and costs associated with actual project start-up are minimized, resulting in less downtime, fewer delays and less unforeseen expenses.

Debugs mechanical, pneumatic and electrical developments

Virtual Commissioning allows companies to debug and optimize the mechanical, pneumatic and electrical developments of their systems prior to physical implementation. This ensures smooth and efficient operation once the project is up and running.

Fixes PLC and robot programming errors

Through virtual simulation, companies can identify and fix programming errors in programmable logic controllers (PLCs) and robots prior to physical implementation. This avoids the cost associated with system errors and malfunctions.

Verifies actual cycle time and project needs

Virtual Commissioning allows companies to verify actual cycle time and project needs prior to physical implementation, ensuring that systems are capable of meeting established production and performance requirements.

Checks operator and machine safety

Safety is a priority in any industrial environment. With Virtual Commissioning, the safety of both operators and machines can be verified prior to physical implementation, reducing the risk of accidents and injuries in the workplace.

Virtual Commissioning: 3 key pillars

We know that it is a very powerful tool that allows companies to simulate and test production systems before physically implementing them, but to better understand this technology, it is important to understand the three fundamental pillars of Virtual Commissioning:

1. Digital Twin

The Digital Twin is the name given to the digital model to be modeled, which includes all the components that collect information about the line as well as the product.

2. Hardware offline programming

Another essential pillar of Virtual Commissioning is the offline programming of the hardware. This process involves the coding of key programmable elements such as PLCs and robots. This programming is thoroughly debugged to ensure that it is error-free and complete in functionality prior to implementation on the production floor.

3. Execution environment

The third pillar is the execution environment, which acts as a bridge between the digital and physical worlds. This digital development environment unifies all programming and physical modeling platforms, allowing them to coexist and interact with each other. The platform is able to interpret the offline programming in the native language of the hardware and act on the digital model to simulate the real response of the actuators and kinematic elements.

Implement Virtual Commissioning in your company with RBX Programming

If you want to take advantage of all the benefits offered by Virtual Commissioning, RBX Programming is a pioneering end-to-end virtual commissioning provider, offering turnkey solutions for global customers, fully customized and customer-driven, always with full transparency and a strong commitment, ensuring maximum profitability and agility in the implementation of projects.