Welcome to the final installment of our virtual commissioning blog series! Throughout these 6-blog series, we’ve explored the complexities of virtual models, tackled commissioning challenges, and highlighted the remarkable benefits companies gain from embracing this technology.
Now, as we conclude this series, we invite you to watch the video below to see virtual commissioning in action, where we will showcase real-world success stories and explore four key scenarios that highlight how Process Simulate tackles specific challenges, showcasing its adaptability and effectiveness across diverse automation environments.
Virtual Commissioning in Action: Real-World Success Stories
LTS’ VP of Technology, Tengyuan Zhang, during his Realize Live presentation, showcased several compelling examples of how virtual commissioning has driven tangible benefits for manufacturers across various industries:
Virtual commissioning success stories from leading manufacturers
The Versatility of Process Simulate: Four Key Scenarios
To further illustrate the capabilities of Process Simulate, Tengyuan presented four distinct scenarios, each highlighting a specific challenge addressed through virtual commissioning:
Scenario 1 – PLC Ladder Logic & HMI Debug:
This scenario focuses on identifying and resolving issues within the PLC ladder logic and HMI. The example shows how Process Simulate can be used to quickly identify and rectify a problem with the manual operation of a conveyor belt, highlighting the benefits of time scaling and online debugging. 
Simulating conveyor belt operation to debug PLC ladder logic and HMI behavior using Process Simulate
Scenario 2 – Safety Verification:
This scenario emphasizes the importance of safety validation in automation. It demonstrates how Process Simulate can be used to create and test various safety scenarios, such as forcing a door open during operation, to ensure the system responds correctly and prevents potential hazards.
Testing safety responses in a virtual environment
Scenario 3 – Robot OLP + PLC Signal Issues:
This scenario tackles a more complex issue involving robot operations and PLC signal interactions. It shows how Process Simulate can be used to pinpoint the root cause of a robot failing to pick up parts due to a signal problem, demonstrating the software’s ability to connect and debug across different platforms (robot, PLC, HMI).
Pinpointing cross-platform signal issues
Scenario 4 – Robot Tool Change Debug:
This scenario focuses on the challenges of robot tool changing, particularly when the release mechanism is controlled by an external PLC. It highlights how Process Simulate can be used to identify and prevent potential damage to equipment by simulating the tool change process and ensuring proper synchronization between the robot and PLC signals.
Preventing equipment damage during tool changes
These scenarios showcase the versatility of Process Simulate and its ability to address a wide range of commissioning challenges, from simple programming errors to complex interactions between different automation components.
Shift Left: Identifying and Resolving Issues Early
One of the core principles of virtual commissioning is the concept of “shift left.” This involves identifying and resolving potential issues as early as possible in the project lifecycle. By utilizing virtual models and simulations, engineers can detect and address problems before they manifest in the physical world, preventing costly delays and rework during the physical commissioning phase. Process Simulate, with its comprehensive features and ability to connect with various automation components, plays a crucial role in enabling this shift-left approach. 
Process Simulate empowers early issue detection with a “shift left” approach to virtual commissioning
Key Takeaways from this Series:
Embrace the Future of Manufacturing
As we conclude this series, it’s clear that virtual commissioning is no longer a luxury but a necessity for manufacturers striving for efficiency and competitiveness in the digital age. As Tengyuan aptly mentioned that the companies who are really taking advantage of virtual commissioning are building up the digital factory of the future. By embracing virtual commissioning and harnessing the power of tools like Process Simulate, manufacturers can unlock new levels of efficiency, innovation, and competitiveness.
We encourage you to explore the full potential of virtual commissioning and discover how it can transform your manufacturing operations. If you’d like to delve deeper into this topic or have specific questions, please don’t hesitate to contact us today at marketing@longtermtec.com or call at 1-800-890-8839.
