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Flexcon Helios

Flexcon Helios is a specialized simulation module designed by Flexcon to evaluate energy use, consumption, costs, and indirect carbon emissions in FlexSim models. It enables manufacturing, logistics, and sustainability-focused professionals to analyze energy flows and related performance metrics across complex industrial systems.

By integrating time-sensitive and contextual energy data with FlexSim’s 3D discrete-event simulation, Helios provides accurate insights into where, when, and how much energy is used during operations – enabling more sustainable and data-driven decisions.

Energy use simulation for sustainable manufacturing

Flexcon Helios enables scenario-based analysis of energy performance in manufacturing and facility processes. It takes into account dynamic variables such as:

  • Energy supply availability and cost fluctuations
  • Carbon intensity variations
  • Load distribution across different energy sources

Users can explore how energy consumption changes with operational timing, layout configurations, and usage patterns – supporting energy-aware planning and optimization.

Integrated with FlexSim logic and objects

Flexcon Helios works natively within the FlexSim simulation environment, supporting both new and existing models.

You can configure any FlexSim object to act as an energy consumer, defining its power usage based on operational state and content.

Power consumption is calculated based on the machine’s operational states, each of which defines a constant consumption rate over time.

Configuration tools include:

  • Energy use policies
  • Consumption rates (state-based or baseline)
  • Source availability and dispatch logic

Simulation results include:

  • Cost-efficiency metrics
  • Energy consumption
  • Power requirements
  • Indirect CO₂ emissions

Dynamic modelling of energy sources

Flexcon Helios models energy sources with realistic and time-sensitive behavior, supporting both constant and variable generation, including scheduled and stochastic availability. The system can represent a mix of renewable and conventional energy supplies, and dynamically adjust energy availability and carbon footprint using external data sources such as ENTSO-E, PVGIS, or custom APIs.

Configuration of scheduled and stochastic energy sources in FlexSim using Helios, including carbon intensity and cost data.

This enables accurate planning and simulation of resilient, sustainable energy systems that reflect real-world operating conditions.

Decision support for energy efficiency

FlexSim model used in energy optimization scenario to evaluate production scheduling strategies with Helios.

By simulating the temporal and spatial dynamics of energy use, Flexcon Helios helps teams:

  • Identify energy-intensive process phases
  • Reduce time in non-productive or high-consumption states
  • Optimize component sizing and power infrastructure
  • Evaluate operating costs and environmental impacts
  • Compare alternative scenarios based on CAPEX/OPEX trade-offs

The analysis relates energy performance to overall system productivity, ensuring a holistic and operationally relevant view.

Baseline simulation of energy consumption under standard operating conditions.
Simulation of an alternative scenario with improved energy performance.

Maintenance and version compatibility

The Flexcon development team actively maintains and regularly updates Flexcon Helios to ensure full compatibility with the latest Long-Term Support (LTS) and Update releases of FlexSim. This guarantees seamless integration, technical reliability, and long-term alignment with the simulation platform’s evolution.

You can download the module here from the Third-Party Modules section of the Downloads page on the official FlexSim user portal.

Contact Flexcon to request a demo if you’re evaluating FlexSim for the first time.

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