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The program version is finished.
Now the plant has to work.

We bring software, peripherals and real sequences together, from the I/O check to the ramp-up.

On the assembled plant, programs meet real sensors, drives and mechanics. Wrong assignments, missing releases or unchecked device parameters can delay the first production runs.

IQstruct Engineering loads the software, supports the I/O check, tests manual functions and accompanies the first parts. Barcode and RFID readers, camera systems and drives are set up. Data connections to customer systems, agreed safety tests and FAT and SAT support are integrated into the sequence.

Start now at no cost

In a free first conversation we clarify scope, time window and location, and say which people we put on it.

See the person in charge

What goes into operation on the plant

Software and control

Programs are loaded onto the control systems; plant and software are adjusted.

Peripherals

Barcode and RFID readers, camera systems, drives and further devices are parameterised and integrated.

Data connections

The agreed connections to customer systems, for example via OPC UA or to the MES, are set up and tested.

Tests and acceptance

Agreed safety tests, quality runs as well as FAT and SAT are integrated into the sequence.

From the virtual test to the real plant

At IQstruct Engineering, virtual and real commissioning form one continuous process.

While the real plant is being assembled, virtual commissioning tests the control software and connected systems on the model. After the I/O check, the version accepted in the virtual FAT is transferred to the real controller. On site, the real installation, mechanics and processes are then tested.

Controllers and plants are then integrated into the customer's IT and production systems. For this we set up connections, for example via OPC UA, check data points and messages and coordinate the interface with the customer's IT.

Changes from real commissioning are fed back into the software, the documentation and the simulation model. The model thus remains usable for training and later conversions.

Conveyor belt with apples, employees at the line behind it

On site

The tested software version meets the real plant

The I/O check, peripherals, data connections and the first parts lead the plant step by step into the ramp-up.

From the first switch-on to the ramp-up

  1. Three people discuss a plant layout at a table, the plan of the production cells on the screenAi

    1

    Discuss process requirements

    Process description, plant layout and interfaces are clarified with your team.

  2. A technician checks the list of inputs and outputs on the screen while a colleague measures at the sensors of the plantAi

    2

    Check the signals

    In the I/O check, sensors, actuators and bus communication are checked against the control assignment.

  3. A technician works on the gripper of a robot in the hall while a colleague follows the cell on the screenAi

    3

    Commission the real plant

    The tested software version goes to the real plant and is fine-tuned there.

  4. Two people check the model of the robot cell on the screen and tick off the acceptance points on a clipboard, the real plant behind themAi

    4

    Ramp-up and handover

    Function tests and quality runs are documented, and the plant then goes to your team.

Project experience

Commissioning battery production for an automotive OEM

IQstruct Engineering has worked with suppliers of an automotive OEM on the virtual commissioning and ramp-up of battery production lines.

The work covers sites in Europe and worldwide. IQstruct Engineering already worked on the virtual commissioning for the production of the predecessor series in Germany.

More references

Frequently asked questions

We are glad to answer your detailed questions in a personal conversation.

Who is responsible for the overall plant?

Responsibility for the overall plant and formal acceptance is defined in the contract. We do not promise a date or a fault-free ramp-up across the board.

Do you accompany quality runs?

Yes. The first parts and test parts run through the plant, and we accompany machine capability studies and further quality runs.

Do you support FAT and SAT?

We prepare tests, carry them out, document the results and work through open points. The legally binding acceptance is declared by the authorised contracting parties.

What happens after the handover?

Support covers fault analysis, software corrections and optimisations, via remote access or on site. Response times and duration are agreed in the contract.

Further industry solutions

Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.

First conversation

Arrange a free first conversation

Describe your task. We agree a date and discuss the possible project scope.

  1. Notebook on a desk with an open calendar and a selected appointmentAi

    1

    You request an appointment

  2. Two people in a meeting room on a video call with three experts, a plant model on the screenAi

    2

    We discuss your requirements

  3. Three people at a meeting table, a project quotation with a plant model on the screenAi

    3

    You receive a quotation for the agreed scope

Tobias Kuck
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 conversation

Not quite what you need?

Discover further suitable services.

Virtual commissioning

Test PLC and robot programs on the digital plant model before real commissioning begins.

Learn more

Functional safety

Implement specified protective functions in control software and test their response on the plant.

Learn more

Training

Use the virtual commissioning model for operation, troubleshooting and restart.

Learn more