Develop the software
Program PLC, robotics and operation for the agreed process.
Engineering, simulation
and virtual commissioning
Automation projects today connect controls, robotics and operational IT.
Assembly is under way while PLC, robot and control system software is still being agreed. Changes at one station bring new interface tests with them, and the time window for the ramp-up stays tight. When faults only become visible on site, acceptance and the planning of the teams involved come under pressure. What is needed is an agreed path from the process requirements to a tested software version at the plant.
For that, tasks, responsibilities and handovers between your team, plant builders and software suppliers have to be settled early.
Start now at no cost
In a free first conversation we establish what can be validated on a model at your plant and which data needs to be available for it.
Simulation, control and software in one project
Process description, software versions and interfaces have to come together into a testable state of the plant.
PLC and robot programs, operator interfaces and production control systems interlock in the plant sequence. We develop and connect these software components, agree interfaces with the trades involved and record changes traceably. Technical project management coordinates work packages and handovers; electrical design is carried out with specialised partners.
Which simulation serves that purpose follows from the question: virtual commissioning tests real control programs against the plant model. Material flow simulation, in contrast, examines throughput, buffers and bottlenecks in the whole system. The two methods provide different grounds for decisions on layout, capacity and ramp-up.
One plant project
Programming, simulation and commissioning work hand in hand
The services of the area work with the same model and software version, from the concept to the ramp-up.
Scope of services
Test on the model
Check control sequences and interfaces before the plant is built.
Accompany the ramp-up
Take over software versions, work through deviations and document the tests.
Services that interlock in the plant project
Ai1
Discuss process requirements
Process description, plant layout and interfaces are clarified with your team.
Ai2
Program the controllers
PLC and robot programs are developed as one coordinated automation concept.
Ai3
Virtual commissioning
The real programs control the model through a bidirectional coupling; the phase ends with an accepted software version.
Ai4
Commission the real plant
The tested software version goes to the real plant and is fine-tuned there.
The right tool for every task
The simulation platform follows the customer specification, the control technology and the project environment.
Existing licences, models and the experience of your team feed into the choice. The coupling to the controller and the later maintenance of the model matter just as much. IQstruct Engineering is a Solution Partner for fe.screen-sim and a Schneider Electric Alliance System Integrator for automation, specialising in digital twins.
Project experience
Commissioning battery production for an automotive OEM virtually
IQstruct Engineering has worked with suppliers of an automotive OEM on the virtual commissioning and ramp-up of battery production lines.
IQstruct Engineering has worked with suppliers of an automotive OEM on the virtual commissioning and the ramp-up of battery production lines. The contributions cover sites in Europe and worldwide. For the production of the predecessor series in Germany, IQstruct Engineering was already active in virtual commissioning. That experience connects the testing of control software on the model with the subsequent work on the real production line.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
Does the simulation replace the test on the real plant?
The simulation tests the modelled behaviour. Real protective functions, installation and mechanics are tested on the plant. Responsibility for other trades and for the overall plant is defined per project.
Are manufacturing execution systems and IT systems included as well?
Yes. Where needed, IQstruct Engineering develops emulations or its own software components for manufacturing execution systems, image processing PCs and other IT applications. Typical interfaces are OPC UA and MQTT.
Who takes care of mechanical and electrical design?
Mechanical design lies with the plant builder. IQstruct Engineering carries out electrical design with partners and aligns it with programming and simulation.
Further industry solutions
Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.
- AutomotiveThe cycle time of a line is settled before it is built, and the buyer asks for proof that it is reached.
- Special purpose machineryEvery machine comes about once, and its control code comes about with it.
- Battery production and e-mobilityNew lines go into operation in quick succession, and their material flow changes with every product change.
First conversation
Arrange a free first conversation
Describe your task. We agree a date and discuss the possible project scope.
Ai1
You request an appointment
Ai2
We discuss your requirements
Ai3
You receive a quotation for the agreed scope
Tobias KuckBusiness Development ManagerTakes up new projects, coordinates offers and accompanies the cooperation from the first enquiry.
Free first conversation
Describe your task in the contact form. We come back with a proposed date.
Arrange a first conversationBooking calendar
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