Simulation and virtual commissioning with TIA Portal

Virtual commissioning with TIA Portal

Reduce time and risk in machine building and plant engineering and lay the foundation for new business models

Faults are inevitable during the development of a machine or plant. However, they can cause high costs and enormous effort when they are only detected during real commissioning. Integration in a line or plant involves risks as well. A solution is simulation with TIA Portal. Based on the digital twin of a new machine or line you’re able to parallelize engineering, test functions and detect faults earlier, simulate the interplay of the machine in a line, and optimize operation while its running. Also, additional services can be offered based on the digital twin of the machine, which can also be used for marketing, i.e. at fairs or in a virtual showroom.

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Digital Enterprise SPS Dialog
Virtuelles Event, Nov 26

Digital Enterprise SPS Dialog

Seien Sie live dabei bei dieser interaktiven, virtuellen Veranstaltung. Erkunden Sie unsere SPS-Highlights in 3D in unserem brandneuen Showroom. Lassen Sie sich von führenden Branchenvertretern inspirieren und diskutieren Sie mit unseren Digital-Enterprise-Experten.

Playing it safe

Save time and money with virtual commissioning

You can play it safe right from the start by using the digital twin of a machine or line: from the concept phase to development to commissioning and optimization during operation. Thanks to simulations and virtual commissioning you’re able to reduce the time to market of new machines and lines, reduce error costs, increase quality, and reduce risks during real commissioning.
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SIMATIC Machine Simulator

The integrated software landscape makes it possible to simulate and validate machines - from simple to complex requirements. This is made possible by our new software bundle for virtual commissioning and the associated simulation tools.


Specific solutions for specific challenges

Machine builders and plant engineers, system integrators and plant operators have different requirements. Simulation provides a number of benefits in any case. In order to make best use of it, we’re providing specific solutions for each use case.

The virtual machine

In order to fully digitalize a machine, it’s necessary to virtualize its three essential elements: automation, electrics, and mechanics. SIMATIC S7-PLCSIM Advanced represents the virtual controller based on the SIMATIC S7-1500 and is required for simulation of the controller software. An open interface lets you connect the virtual SIMATIC controller to a variety of other simulation tools. An example is SIMIT, which represents the electrical behavior. In order to complete the digital twin of machine it’s necessary to include and simulate mechanics and kinematics. This is a task for NX Mechatronics Concept Designer.

The virtual production cell

Before integrating a machine into a production line, it’s possible to validate the interplay of a superimposed controller with robots and the creation of complete robot programs. This facilitates the design of cells and the validation of workflows in complex manufacturing lines with many interacting robots.

The virtual line

The virtual line comprises several simulation models: a discrete event-oriented simulation model that simulates material flow. A communication model that comprises interfaces to automation and third-party tools. And an automation model that enables to simulate a controller.

For machines with SIMATIC S7-1500

Simulations are also useful to optimize machines during operation. This way you can realistically verify and validate the automation in complex mechatronic systems and processes, even if the hardware configuration isn’t finished yet. Fast simulation cycles and synchronization also enable optimizing the control strategy including closed-loop applications like PID controllers.


Highlight videos about virtual commissioning with TIA Portal

Learn from our customers and experts about the benefits that virtual commissioning of automation solutions can provide in practice.
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Further information

With the Digital Enterprise Suite and Totally Integrated Automation (TIA), you have access to all the tools and technologies you need to take optimal advantage of virtual commissioning and experience the benefits of digitalization in actual practice.

Successful use of virtual commissioning

Companies from a wide range of industries are successfully using virtual commissioning. Here’s an example.

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Simulation in a virtual environment yields real-world benefits

The virtual commissioning of controllers, HMIs, machines, and production lines decreases time and costs, reduces the risk of errors and defects, and achieves the desired results more quickly. With TIA and the TIA Portal as the engineering framework, you have access to all the relevant data on your hardware and the software tools that will enable you to develop, simulate, and optimize in a completely virtual environment. 

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