Virtual commissioning is now a standard requirement for many of the world’s biggest and best automakers. This is a development over recent years due to the clear demonstration of the dramatic cost saving and increased efficiency that it enables during the implementation stage, as well as futureproofing the facility for future models.
Process Simulate is integral to our project workflows, focusing on the effective integration of PLC and robot programs. It's essential for our virtual commissioning, enabling us to test safety devices, validate concepts, and identify hardware faults in a virtual environment, ensuring reliable system operation before going live.
Virtual commissioning is the process where the PLC and robot programmes are tested together in harmony in a virtual environment using process simulate software.
On average it saves 40% of onsite commissioning time, as the interface and interaction has been fully tested and optimised in advance, often before any equipment has been physically installed on site.
The offline simulation study is a digital twin of the physically equipment on site. In the instance of brand-new greenfield sites, simulation is often master and upon physical installation on site, our mechanical partners cell align / measure the physical equipment, providing us with measured data to implement into our OLP’s, thus maintaining complete alignment.
In the instance where customers wish to use virtual commissioning to limit the risk of implementing changes / cycle time improvements of existing lines, or to complete early stage feasibility studies, 3D scans are conducted and fed back into simulation, once again ensuring a match with the digital twin.
Having a simulation study that matches the real world gives our customers the confidence to implement improvement works in short periods of time where they would usually not be feasible. In turn, this can significantly reduce the time to market for any new models / vehicles and enable our customers to ensure complete process efficiency.
Another major benefit is by establishing a risk-free environment to be able to conduct testing of the production lines, in a controlled way, significantly quicker than doing so on site. There is no limit to the extent of testing that can be done In the virtual world, however many OEM’s have their own predefined check list.
At Prologik Automation, we are dedicated to excellence and professionalism.
Our commitment is reflected in the following accreditations:
