The ever-evolving Industry 4.0 is driving manufacturers to look for ways to improve efficiency, quality and profitability. Virtual commissioning, an innovative approach that uses digital twins to simulate and optimise manufacturing processes, is emerging as a key solution.
In this article, we explore the concept of virtual commissioning, its varied applications, and how it is revolutionising the way manufacturers work.
What is virtual commissioning?
Virtual commissioning is an advanced simulation method for virtually testing and validating automated systems and production processes before they are physically built.
This approach begins with the creation of a detailed 3D digital model, faithfully reproducing the equipment or production line, including the physical characteristics and interactions between components. This model can be used to simulate and test different configurations, parameters and operating scenarios, optimising performance and resolving potential problems before the equipment is actually commissioned.
Why virtual commissioning ?
Virtual commissioning offers many advantages for manufacturers. It can be applied to product design reviews, production feasibility assessments and ergonomic analysis of workstations.
1. Cost reduction
Virtual commissioning reduces the cost and time taken to commission equipment by identifying and resolving potential problems in a virtual environment. This reduces costly downtime and production delays. In addition, by optimising performance at the design stage, maintenance costs are reduced and equipment life extended.
2. Improving quality and optimising performance
Manufacturers and designers can not only improve the quality and reliability of end products by testing equipment under realistic conditions at the design stage, but also optimise the performance of existing production lines. By simulating and testing various configurations, parameters and scenarios, they can effectively identify bottlenecks and potential inefficiencies. As a result, they avoid quality problems and costly recalls once the equipment is in real service.
3. Flexibility and adaptability in equipment design
The use of virtual twins offers manufacturers exceptional flexibility. From the design phase onwards, designers can explore different configurations, adjust parameters and test scenarios, facilitating rapid adaptation to market changes. This approach reduces the risks associated with new developments while improving equipment quality and reliability. By allowing in-depth exploration of design options, the process becomes more flexible, enhancing the overall efficiency of industrial design.
4. Training and skills development
Virtual commissioning is not only a tool for design, but also for staff training. Using digital twins, manufacturers can simulate and test different operating and maintenance procedures, enabling operators and technicians to acquire the necessary skills before actual commissioning.
5. Ergonomic analysis of workstations
This approach offers a significant advantage in the ergonomic analysis of workstations by enabling designers to assess the ergonomics of workstations via virtual simulations.As well as analysing operators' movements, this helps to ensure their well-being by reducing the risk of musculoskeletal disorders.Manufacturers can thus increase operational efficiency by designing more ergonomic and productive working environments.
These realistic physical simulations enable engineering process evaluations and virtual prototyping, which is essential for optimising industrial operations.
XR Twin : your virtual commissioning solution
The implementation of virtual commissioning relies on advanced technological tools, in particular virtual reality software and virtual twins, which are essential for the creation and simulation of the latter.
XR Twin is industrial review creation software that is accessible to everyone. It stands out for its ease of use, enabling you to configure a digital twin from data without requiring any programming skills. You can import your data, whether CAD models, 3D models or point cloud files, to create your simulation.
In a context where Industry 4.0 is advancing rapidly, the adoption of the virtual commissioning approach is becoming essential to remain competitive in the global marketplace. By investing in advanced technological tools and harnessing the potential of digital twins, manufacturers can not only improve performance, quality and profitability, but also position themselves as leaders in Industry 4.0.
Our team of experts will be delighted to help you harness the potential of virtual commissioning in your business.