Emulation for FlexSim: Test Automation Without Risk

In industrial automation, every plant must operate with precision and reliability.
However, testing control software directly on real machines can be risky and costly. Production interruptions, machine downtime, and other unexpected issues can cause delays and increase commissioning costs.

For this reason, companies across different industries worldwide are using Flexcon Emulation for Autodesk FlexSim. This tool enables users to test and validate PLC logic in a virtual environment.

By simulating machine behavior before its actual implementation, it is possible to identify and correct potential errors without stopping production. As a result, the commissioning process can be optimized, ensuring smoother integration between control software and physical systems.

Use Case: Integration Between PLCSIM Advanced and FlexSim

A concrete example comes from Sebastian Hemman of Pro-Sim Ingenieurbüro für Prozesssimulation, a FlexSim distributor in Germany based in Brunswick (www.fs-ad.de).
His project demonstrated the use of Ladder logic developed in Siemens TIA Portal and simulated in PLCSIM Advanced. The logic was used to control a transport system modeled in FlexSim through the Flexcon Emulation add-on.
This approach makes it possible to verify PLC logic without directly intervening on the physical system.

In questo video, il team tedesco di Ingenieurbüro für Prozesssimulation mostra come sia possibile testare una logica Ladder complessa, sviluppata in TIA Portal e simulata in PLCSIM Advanced, direttamente su un modello 3D dell’impianto costruito in FlexSim. Tutto questo grazie al modulo Emulation, sviluppato da Flexcon.

Specifically, the system consists of two conveyor chains and a conveyor belt for bulk materials, controlled by PLC logic. The PLC receives inputs from two photoelectric barriers and a scale. The system must therefore operate according to a precise sequence:

Phase 1: only one of the two chains is active.
Phase 2: when a container blocks the first photoelectric barrier, the chain stops and the conveyor belt starts to load the material.
Phase 3: when the scale detects the target weight, material transport stops. If the second barrier is clear, both chains restart.

Thanks to Flexcon Emulation, these steps can be tested in a virtual environment, allowing each operation to be verified without risks to the physical system.

Why Is Emulation So Useful?

Reduces risks: enables control logic to be tested and optimized without impacting the real system.
Lowers commissioning costs: by avoiding tests on physical machinery, commissioning time and costs are reduced.
Improves collaboration: facilitates cooperation between automation engineers and designers by integrating control software with realistic models.

Beyond FlexSim: The Added Value of Flexcon

Flexcon operates in industrial simulation and process optimization. Since 2006, we have supported companies in analyzing and solving complex challenges in production, automation, and logistics.

Autodesk FlexSim is one of the technologies used in our projects. Flexcon’s offering also integrates consulting, development, and vertical solutions designed to address specific industrial needs.

This experience has also led to the development of Flexcon Emulation, Flexcon Helios, and Flexcon Eidos, modules that extend FlexSim’s capabilities in specific areas: from connection to automation systems and virtual commissioning, to energy analysis and AI-assisted simulation workflows.

In this article, we explored Flexcon Emulation, designed to connect FlexSim models with automation systems and the different levels of the industrial architecture. If you already use FlexSim, you can download Flexcon Emulation directly from our download area.

Not using FlexSim yet?
Find out which solution best fits your needs or how to get started: contact us at info@flexcon.it.