Test real programs on the model
PLC, robotics, devices and connected systems are coupled within the agreed test scope.
AiAssembly is under way. Your software
is already being tested on the model.
Virtual commissioning moves control tests into the time before the plant is built.
The plant is still being assembled, but the date for the ramp-up is already fixed. PLC, robotics and connected systems have to work together while changes keep coming in. If testing only happens on the real machine, troubleshooting and rework tie up the specialists on site; open acceptances can also postpone agreed payments. An early, agreed test of the control software creates room for corrections before they weigh on the ramp-up.
Model boundaries, test cases and the handover to the real machine have to be agreed with all trades involved.
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.
Scope of services
Secure changes before the ramp-up
Software versions and model are updated together.
Keep using the model after acceptance
Operator training, variants and conversions can build on the existing model.
A model that behaves like the plant
Design data, circuit diagrams and sequence descriptions are turned into a plant model against which the real control programs run.
Axes and motors receive their movements, and dependent parts are connected into kinematic chains. Workpieces carry the data the sequence needs in addition to their geometry. Virtual sensors and cameras read Data Matrix codes, barcodes or RFID tags, and stoppers on the roller conveyors hold the material wherever the real plant holds it.
Every relevant component receives a behaviour model, from the pneumatic cylinder on the valve to the door safety switch on PROFINET. The PLC and robot programs control the model through the same signals as the plant later on, and the feedback travels the same way back. Program sequences can thus be run in full, observed and tested reproducibly.
If manufacturing execution systems, image processing PCs or IIoT applications belong to the process, IQstruct Engineering develops suitable emulations and interfaces, for example via OPC UA or MQTT. The level of detail follows the test objective. Physical effects that can only be assessed on the real plant remain part of on-site commissioning.
AiAfter acceptance
The model keeps working
Training, conversions, variants and retests of changed software build on the existing model.
Four phases to an accepted software version
Each phase ends with a result on which the next one builds.
Ai1
Understanding and enablement
Project goals, test objectives, roles, data and model boundaries are agreed with the departments involved.
Ai2
Validation and modelling
Design, electrical and process data are checked and built up into kinematics, sensors, conveyor technology and behaviour models.
Ai3
Virtual commissioning
The real programs control the model through a bidirectional coupling; the phase ends with an accepted software version.
- Ai
4
Training and reuse
The model then serves for training, variants, conversions and retests of changed software.
What is tested on the model
Rare or critical states can be repeated on the model under control without blocking the real plant.
Control commands and feedback
Components receive the right commands and report their states correctly to the controller and robot.
Interlocks and releases
Dependencies between stations, devices and operating modes are run through completely.
Automatic mode and special processes
The automatic sequence, infeed and outfeed operations and special plant modes are tested within the agreed scope.
Fault and restart
Fault and restart situations are triggered and observed insofar as they belong to the test objective.
The right tool for every task
The platform follows the customer specification, the control technology, the existing tool landscape and the test objective.
Cameras, drives and IT-related components influence the control behaviour. For these, IQstruct Engineering integrates suitable simulations or emulations and adds custom software.
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.
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.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
Which tests are still required on the real plant?
Virtual commissioning tests the modelled behaviour. Tests of the real installation, mechanics and protective functions on the plant remain necessary. The model boundary is defined jointly before the model is built.
Which documents are needed for the quotation?
Useful are layouts, sequence descriptions, electrical circuit diagrams, CAD data of the plant and the workpieces, PLC and robot programs and overviews of PROFINET and the connected systems. We clarify what is missing when we review the enquiry.
How are the test cases documented?
Each test case is recorded with its test date and result. The list documents the test progress and serves as the acceptance document at the end; its form can be adapted to customer specifications.
What is handed over at the end?
The handover comprises the simulation model, its technical documentation with the software versions used, operating instructions for the model and the test and acceptance documentation. If IQstruct Engineering also did the programming, the PLC project is included.
How does the tested version reach the real plant?
Ideally, assembly and virtual commissioning run in parallel. After the I/O check on the real plant, commissioning starts with the virtually tested software version; changes made on site are then fed back into the model.
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
The booking calendar appears here. It loads only after your consent, because your browser connects to Microsoft in the process.
Not quite what you need?
Discover further suitable services.
PLC programming, HMI and SCADA
Connect sequence control, operation and diagnostics in one coordinated automation concept.
Material flow simulation
Compare cycle times, buffers and utilisation before you decide on layout or capacity.
Training
Use the virtual commissioning model for operation, troubleshooting and restart.