Companies require high quality in their new automated solutions at a low cost and fast delivery. Therefore, test and validation processes become critical for OEMs and system integrators. The testing of the automated systems usually takes place during the on-site commissioning once personnel install the equipment in the actual plant. Incidents at this stage could lead to missing the initial planning. In more severe cases, they may damage the equipment and generate unnecessary additional costs.

Virtual Commissioning

The concept of Virtual Commissioning (VC) is based on realizing the verification and validation of systems against a virtual model instead of in a real automated system.
Different tools and technologies are available in the market for VC.

They use different techniques, such as simulation and emulation, including functionalities focused on different automated systems. Industrial automated system models created using simulation techniques try to provide a similar behavior to the system.

Simulation and Digital Twin

Digital Twin (DT) has increased in popularity recently. From the simulation point of view, it’s a concept for describing a new wave in modeling and simulation. Simulation tools initially supported only the design stage, but today they also support testing, validation, and optimization. In the automated industry, we could define a DT as a multiphysics and multiscale simulation model that mirrors the corresponding physical twin, allowing the extension of simulation to all life cycle phases of the system.

Simulation in Control Testing

Simulation is used to reduce the time and costs associated with control system development and testing by taking much of the task off the project’s critical path.
Without Virtual Commissioning, teams can properly test control systems only after installing the actual equipment, complete with products.
A virtual model replaces the real equipment, allowing teams to develop and test control systems in parallel with other project activities and in an office environment instead of a factory or warehouse.
This approach produces a more thoroughly tested control system while reducing delivery time and project costs.

Our virtual commissioning models are connected to external control systems, usually on programmable logic controllers or PLCs.
Models may also be connected to any control or data acquisition system using many methods, including HTTPS, TCP/IP, UDP, and sockets.

Modeling Framework and Control Languages

Our technology is unique among industrial modeling systems in offering a choice of control methods to suit the different requirements of its broad range of users.
Control methods fall into two categories – those which are integrated within the products and which are therefore operational at the model clock speeds, and those which are external to the products and run in real time. They communicate with the models using OPC, sockets, Modbus, or other product-specific communications :

• Flexscript, C++/Visual Studio, Phyton, C#/Visual Studio (internal).
• Process Flow, Process Modeler (internal).
• Programmable Logic Controllers (external).
• Co-simulated Virtual PLC (external).

Emulation extended usage

Employing emulation beyond development and validation helps train expert users and operators, increases system stability and reliability, and supports system upgrades or modifications without compromising actual production. Teams can also use it during the design phase to support design decisions, facilitate the sales process, and improve initial discussions with customers. In addition, they can use emulation to optimize industrial systems and achieve more efficient operation and higher performance. The effort required to build an emulation model depends on the complexity of the system, but using emulation throughout multiple phases of the system life cycle quickly offsets this investment.
This way, emulation would be worth even for those less complex or critical systems.

High Level Emulation

High Level Emulation (HLE) is “Implemented where models already have low-level controls detailed internally, allowing for higher level emulation of larger systems.”

This is usually for testing material flow controls and corresponding warehouse control systems (WCS/WMS).

High Level Emulation supports testing of warehouse and overall system automation software without involving lower-level controls or the individual components of a larger automated system.
High Level Emulation consists of models connected with PLC (simulated or wired), Process Data Hub, Process Data Collection Systems, and possibly coupled with other simulation tools (co-simulation).

Low Level Emulation

Low Level Emulation (LLE) “Implemented to test lower-level controls such as PLC logic on smaller parts of an overall system”.

This requires the ability to model all 3D aspects in detail, including complex kinematics and physics constraints. Accurate 3D dynamic models can then represent individual machines or their components and connect directly to a PLC program.

Low Level Emulation main drawback is the limited usage with overall systems models because massive 3D graphics limit the simulation/emulation performance.
Low Level Emulation consists of models connected with PLC (simulated or wired), Virtual Controls, Drives, and Automation Frameworks.

Flexcon Emulation: A Virtual Commissioning Module for FlexSim

Flexcon Emulation is an advanced module within the FlexSim simulation software, designed to facilitate virtual commissioning for manufacturing systems. By utilizing Flexcon Emulation, users can simulate the behavior of physical components and control logic in a virtual environment, reducing the need for costly prototypes and minimizing errors during real-world deployment.

Flexcon Emulation module integrates seamlessly with FlexSim’s 3D simulation environment, offering a digital twin of the production system. It allows the emulation of control systems, such as PLC, conveyors, and other automated machinery, ensuring that all components work together as expected.

By incorporating real-time feedback from both the simulation and the emulated control system, Flexcon Emulation ensures the system is optimized for performance, reliability, and safety.

It supports collaborative efforts between system designers, engineers, and operators, enabling them to fine-tune parameters and make adjustments before physical assembly begins, ultimately improving efficiency and reducing downtime in the final commissioning phase.

Flexcon Emulation: Key Concepts

Flexcon Emulation creates a link between FlexSim and external PLCs or clients/servers that communicate with PLCs. It can create multiple connections and define variables for each of those connections.

This tool supports multiple protocols, including Modbus, OPC DA, OPC UA and manufacturer specific like Allen-Bradley, Siemens and Beckhoff.

Modbus and OPC DA connections are freely available from the Flexcon Emulation setup, other connections require an Emulation license, coupled with a FlexSim commercial or educational license.

Flexcon Emulation provides different types of emulation variables, including Sensors (PLC Inputs) and Controls (PLC Outputs).

Sensors write data to the PLC, server, or data variable. When the sensor connection is active, any change in its value writes the updated data directly to the PLC.

Controls are used to read data from the PLC, server or data variable. A control can only be changed if the control’s connection is inactive.

Users can manage emulation variables through the module’s GUI, FlexScript, or ProcessFlow.

Flexcon Emulation: Available Connectors

Flexcon Emulation Module provides Basic and Advanced Connectors.

The “Emulation Basic Connectors” set includes OPC/DA and Modbus RTU and is available in all FlexSim product configurations.

The “Emulation Advanced Connectors” set includes OPC/UA, Siemens S7, Siemens PLCSIM Advanced, Beckhoff ADS / Twincat, Allen-Bradley, Mitsubishi MC, Mitsubishi MX and MQTT connections.

For a complete overview of the module capabilities, visit the Flexcon Emulation product page.

Contact Flexcon to discover our emulation-driven solutions.