Virtual Commissioning and Testing represents a transformative approach in modern manufacturing that fundamentally changes how production systems are designed, tested, and optimized. Virtual commissioning is reshaping the manufacturing landscape by employing computer simulations for testing and optimizing production systems before they’re physically built.
This methodology bridges the gap between digital design and physical implementation, enabling manufacturers to validate their systems in a risk-free virtual environment before committing resources to physical construction.
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9.1.1 Virtual environments for testing robot setups and production scenarios
9.2.1. Introduction to Virtual Commissioning
9.2.2 Tools for integrating sustainability KPIs in virtual commissioning
9.2.3 Metrics to evaluate robot designs and production line efficiency
At its core, Virtual Commissioning (VC) is a simulation method that connects control systems to virtual models of components, machines, or entire plants. Virtual commissioning (VC), defined as the simulation and testing of systems in a virtual environment before physical implementation, plays a key role in addressing the challenges of integrating and validating complex systems efficiently and effectively.
This approach allows engineers to test and optimize production processes, robot programs, and control logic in a digital twin environment that accurately represents the physical system’s behavior.
The project’s vision of virtual commissioning that not only test system functionality but also assess sustainability impacts and optimize energy consumption.
Virtual commissioning in the MODAPTO context encompasses two main aspects: behavior and geometry simulation without a real plant, and process analysis based on recordings from real plants. This dual approach enables comprehensive testing of both theoretical designs and practical implementations. The integration of tools like RF::SUITE, Functional Mock-up Interface (FMI) standards, and specialized co-simulation engines creates a powerful ecosystem for virtual testing and optimization.
A distinguishing feature of the MODAPTO approach is the seamless integration of sustainability assessment into the virtual commissioning process. By incorporating Functional Mock-up Units (FMUs) that calculate energy consumption and carbon emissions, the framework enables manufacturers to evaluate environmental impacts during the design phase rather than after implementation. This proactive approach to sustainability represents a significant advancement in responsible manufacturing practices.
The purpose of this learning module is to equip manufacturing professionals, engineers, and technical managers with comprehensive knowledge and practical skills in virtual commissioning and testing within the context of modular manufacturing systems. This module addresses the critical need for professionals who can leverage advanced simulation technologies to design, test, and optimize production systems before physical implementation.
By identifying and resolving issues in the virtual environment, companies can avoid expensive modifications to physical systems.
Second, virtual commissioning enhances safety by allowing engineers to test dangerous scenarios and error conditions without risk to personnel or equipment. Testing these under real conditions is of course not possible due to the potential danger to employees and workers. However, thanks to virtual commissioning, it is possible: the simulation allows all fault scenarios to be programmed and tested to see how the machine would behave in an emergency. This helps to uncover potential safety gaps and to eliminate them during the design phase.
Third, the integration of sustainability assessment into virtual commissioning aligns with global manufacturing trends toward environmental responsibility. The ability to evaluate energy consumption, carbon emissions, and resource utilization during the design phase enables companies to make informed decisions that balance productivity with environmental impact. This capability is particularly relevant as manufacturers face increasing pressure to meet sustainability targets and comply with environmental regulations.
The module also addresses the growing complexity of modern manufacturing systems. As production lines become more interconnected and automated, the need for comprehensive testing before physical implementation becomes critical. Virtual commissioning provides a platform where complex interactions between robots, PLCs, sensors, and other equipment can be thoroughly tested and optimized.
Furthermore, this module serves the purpose of preparing professionals for the future of manufacturing, where digital twins and virtual testing will become standard practice. By mastering these technologies now, learners position themselves at the forefront of Industry 4.0 and contribute to their organizations’ digital transformation initiatives.
This learning module is designed for a diverse audience of professionals involved in manufacturing system design, implementation, and optimization. The primary target audience includes:
Virtual Commissioning Engineer in “Manufacturing Engineer and system integrator”
Manufacturing Engineers and System Integrators: Professionals responsible for designing and implementing production systems will benefit from understanding how to use virtual commissioning tools to validate their designs before physical implementation. These individuals need to understand both the technical aspects of simulation and the practical considerations of system integration.
Automation Engineers and PLC Programmers: Those who develop control logic and program industrial controllers will learn how to test their code in virtual environments, reducing debugging time during physical commissioning. Thoroughly test and debug automation control logic and PLC code in a digital environment, minimizing the need for extensive debugging during ramp-up and after deployment on the production floor. Identify and resolve potential issues in automation control logic, safety interlocks and PLC code when they are much easier to fix, reducing the overall costs of commissioning, debug and rework before startup.
Robotics Engineers and Programmers: Specialists working with industrial robots will learn how to use virtual commissioning for offline programming, trajectory optimization, and cycle time reduction. The module covers robot-specific simulation tools and techniques for optimizing robot movements while considering energy efficiency.
Sustainability Managers and Environmental Engineers: Professionals focused on reducing environmental impact will learn how to integrate sustainability KPIs into the design process through virtual commissioning. The module provides practical knowledge on using FMUs for energy and carbon emission calculations.
Production Managers and Manufacturing Leaders: Decision-makers who need to understand the strategic benefits of virtual commissioning for their organizations. These individuals will gain insights into how virtual commissioning can reduce costs, improve quality, and accelerate time-to-market.
Digital Transformation Specialists: Professionals leading Industry 4.0 initiatives will learn how virtual commissioning fits into broader digital manufacturing strategies and how it enables the creation and validation of digital twins.
Students and Researchers: Advanced students in manufacturing, robotics, and industrial engineering programs, as well as researchers exploring next-generation manufacturing technologies, will find valuable theoretical foundations and practical applications.
The module assumes participants have basic knowledge of manufacturing processes and some familiarity with automation concepts. However, it is structured to accommodate varying levels of technical expertise, with foundational concepts explained before advancing to more complex topics. Participants should be comfortable with computer-based tools and have an interest in simulation and digital technologies.
Upon successful completion of this module, participants will achieve comprehensive competencies in virtual commissioning and testing for modular manufacturing systems. The learning outcomes are structured to ensure both theoretical understanding and practical application skills.
Technical Competencies:
Analytical and Problem-Solving Skills:
Strategic and Management Competencies:
Practical Application Skills:
These learning outcomes ensure that participants understand the theoretical foundations of virtual commissioning. The emphasis on sustainability integration and modular manufacturing concepts aligns with current industry trends and prepares learners for future developments in manufacturing technology.
To successfully engage with and benefit from this Virtual Commissioning and Testing module, participants should meet certain prerequisites and have access to specific resources. These requirements ensure that learners can fully comprehend the technical content presented throughout the module.
Educational and Knowledge Prerequisites:
Technical Infrastructure Requirements:
Professional Context Prerequisites:
Learning Readiness Requirements:
Recommended Preparation: For those who may not meet all prerequisites, we recommend preliminary study in areas of weakness. Online resources, introductory courses in industrial automationcan help bridge knowledge gaps. The module includes supplementary materials for quick reviews of essential concepts, but these are not substitutes for the foundational knowledge outlined above.
Meeting these requirements ensures that participants can focus on mastering virtual commissioning concepts rather than struggling with prerequisite knowledge, leading to a more productive and rewarding learning experience.
