Virtual Commissioning
We test your control logic against a simulated model of the line, so the day you switch it on is not the day you find out what is wrong.
Service Overview
The control system is usually the last thing tested and the first thing to hold up a start-up. Virtual commissioning tests it first. We connect your PLC and control logic to a simulated model of the line and run it, so the faults, deadlocks and sequencing errors surface in software, weeks before any of it touches real hardware.
What We Deliver:
PLC & Control Logic Testing
Your actual control code connected to a simulated model of the line, running the real sequences against real sensor and actuator behaviour. Logic errors, deadlocks and race conditions get found against a model that cannot be damaged, on a schedule that cannot be delayed by finding them.
Sensor, Signal & Interlock Validation
Every sensor, signal, interlock and safety condition exercised against the simulated line before the wiring is confirmed. Missing signals, inverted logic and interlocks that fight one another turn up in software rather than during a start-up with everybody standing around watching.
Fault & Edge Case Simulation
The failure modes you would never deliberately create on a real line — jams, part absence, e-stops, power loss, sensor failure — triggered and recovered from safely in the model. The recovery routines get tested properly, which on a real line almost never happens.
Operator & HMI Validation
The interface your operators will actually use, driven against the simulated line, so the screens, alarms and recovery sequences get reviewed by the people who will live with them while changing them still costs nothing but time.
Start-Up Support
On-site support when the line goes live, closing the last gap between the model and the machine. We work alongside your integrators and your maintenance team, so the understanding stays in the building after everybody else has gone home.
Value We Create:
Start-Up Without The Fire Drill
The chaotic first week of a commissioning — logic rewritten on the fly, sequences patched, everybody in the room and nothing running — happens weeks earlier, in software, with nobody watching and nothing at stake but time.
Failure Modes Tested Properly
On a real line, nobody deliberately jams the machine to see what happens. In a model you can, over and over, until the recovery routine actually works. The edge cases that would have found you at three in the morning get found on a Tuesday instead.
Control Software That Arrives Working
The logic reaching your line has already run against a model of that line. What normally gets discovered during a start-up, with production waiting and an integrator billing, has already been discovered, understood and fixed.
Integrators Held To A Standard
When the control code is testable against a model, it becomes reviewable. The quality of what your integrator delivers stops being something you take on trust and starts being something you can check before you accept it.
A Line That Comes Up On Schedule
Start-up is where capital projects lose their last few weeks, and where those weeks are the most expensive ones in the programme. Testing first means the date you gave the board is the date the line actually runs.
Switch it on twice — once in software
Send us the control narrative and the layout. We will tell you what your start-up is likely to find.