Virtual Commissioning
Connect real PLC code to a physics-based virtual line to validate sequences, interlocks, material flow, and recovery before hardware startup
Our role
We built the physics-based Unity model, implemented the I/O and controller connections, and worked with automation engineers to validate real PLC logic against representative machine behavior.
The Problem
Full production lines are often integrated for the first time on the shop floor. PLC programs, robot sequences, interlocks, and material flow only meet in reality, which turns commissioning into waiting, rework, and knowledge trapped in whoever is on site that week.
- Automation software cannot be exercised realistically until hardware assembly is far along
- Sequence errors and station handoff faults surface late when mechanical and software changes are costly
- FAT preparation lacks a repeatable test environment, so acceptance depends on who is present and what can be run
Why It Matters
Late discovery of logic and flow problems consumes project margin and customer trust. Moving verification into a connected digital line makes startup predictable and FAT preparation substantive instead of aspirational.
- Coverage of critical sequences tested before physical assembly is complete
- Readiness of FAT scenarios and evidence before the customer arrives
- Stability of line behavior after handover to production
Our Solution
Unity simulation of the multi-station line with representative physics, sensors, actuators, kinematics, buffers, and product flow
Bidirectional coupling to Siemens and Beckhoff PLC environments so real programs drive the digital line
I/O mapping and timing behavior that let the production PLC programs interact with the model as they would with physical equipment
Logic validation across normal cycles, handoffs, interlocks, stops, resets, and recovery conditions before hardware availability
Results
Line logic first tested on assembled hardware with limited time and high change cost
PLC-connected virtual line where critical flows are proven before FAT and site installation
- Fewer surprises at FAT because sequences and interlocks were exercised early
- More focused physical commissioning time spent on real integration gaps, not basic logic faults
- Stronger customer confidence through demonstrable test evidence before the line ships
Project context
A machine builder developing a multi-station production line needed to exercise PLC logic and station coordination before mechanical completion. neexo translated the line design into a physics-based Unity model, connected Siemens and Beckhoff control environments, and supported iterative logic validation across sequence, flow, interlock, and recovery behavior.
Deliverables
- Physics-based Unity line model with sensors, actuators, products, and representative material flow
- I/O mapping and connected Siemens and Beckhoff controller test environment
- Logic-validation scenario set covering cycles, handoffs, interlocks, stops, resets, and recovery
Related reading
Guides
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