Flexcon Emulation is an advanced module developed by Flexcon to enable structured Virtual Commissioning within the FlexSim 3D simulation environment. By connecting real or virtual control systems to a dynamic digital model, it allows engineers to validate automation logic and system behavior before physical installation.
The module bridges simulation and real control software, providing a controlled environment for automation validation, PLC testing, and I/O verification.
Flexcon Emulation supports a control-integrated Digital Twin, enabling real automation code to interact directly with a dynamic 3D model. This approach represents a practical implementation of simulation for Virtual Commissioning in modern Industry 4.0 automation environments.
Virtual Commissioning consists of validating automation systems against a virtual model instead of the physical plant. Flexcon Emulation enables PLC testing in a virtual environment by synchronizing FlexSim models with external control systems, including PLCs, WMS, MES, AGV managers, SCADA platforms, and robotic controllers.
Through real-time communication between the simulation model and control software, the platform executes real PLC code inside a safe and structured environment, supporting:
This methodology shifts critical validation activities earlier in the project lifecycle, improving cross-functional collaboration and reducing startup risk.
For a deeper overview of emulation applications and methodologies, read our article on Simulation and emulation for system design.
Flexcon Emulation creates a bidirectional link between FlexSim and external controllers. It supports configuration of multiple connections and enables definition of dedicated variables for inputs, outputs, and data exchange.
Automation and project teams configure emulation variables through graphical tools, FlexScript, or ProcessFlow logic, aligning configuration activities across the project lifecycle.
This structured approach supports industrial control system integration and enables reliable automation lifecycle optimization.
Flexcon Emulation supports the development of a Digital Twin connected to real PLC systems, where the 3D simulation model interacts directly with live automation logic.
This approach allows mechanical design and control development to progress in parallel. It also enables simulation-based control testing before equipment installation, improving predictability during final commissioning and ensuring higher system reliability.
What does Flexcon Emulation enable?
Validate automation systems in a virtual environment before physical installation.
Connect simulation models directly to real industrial control architectures.
Flexcon Emulation supports structured integration with industrial PLC and automation platforms.
The overview below summarizes the available Basic and Advanced connector categories supported by the module.
Flexcon Emulation replicates realistic operational behavior, including timing, event handling, sensor responses, and fault conditions within a structured Virtual Commissioning environment. It enables the simulation of abnormal scenarios, restart procedures, and control failures in a safe Digital Twin environment.
Beyond commissioning, emulation models can support system upgrades, optimization activities, operator training, and lifecycle validation, extending the value of Simulation for Virtual Commissioning across the entire automation lifecycle.
By enabling early and iterative control testing, including PLC validation in a virtual environment, Flexcon Emulation improves system robustness, reduces on-site commissioning time, and lowers overall project risk, supporting higher Manufacturing Efficiency in modern Industry 4.0 and Smart Factory projects.
Contact Flexcon to explore full Virtual Commissioning capabilities of Flexcon Emulation.
