Glossary · Engineering, integration and validation
Virtual commissioning
Also known as: VC, Virtual start-up
German: Virtuelle Inbetriebnahme
In automation engineering, virtual commissioning is the testing and commissioning of control software against a simulation model of the machine or plant before the physical equipment is available. The real or emulated controller exchanges signals with the model as it would with the real plant.
- Validation
In one sentence
Virtual commissioning tests and commissions control software against a simulation model of the machine or plant before the equipment exists.
Example
Weeks before installation, the team runs the robot cell's PLC program against a 3D model of the cell and fixes a collision between the robot and a clamp.
How it applies
- Engineering: A behavioral model of the plant, often with a 3D view, is connected to the controller. Engineers test sequences, interlocks, HMI screens and interfaces during the design phase.
- Commissioning: Many errors are found and fixed in the office, which shortens physical Commissioning on site. Tests on real equipment remain necessary, especially for wiring, mechanics and safety functions.
- Training: The same model can be used to train operators before start-up.
- Documentation: Virtual commissioning gives the documentation team early access to realistic HMI screens and sequences, so manuals can be drafted and checked before the machine exists. Note the model and software versions the drafts are based on.
Virtual commissioning vs. digital FAT
Virtual commissioning is an engineering activity to find and fix errors. A Digital factory acceptance test is a formal acceptance test with the customer, performed on a similar simulation setup. Both rely on the fidelity of the model.