Digital Twin Software That Advances PLC Testing

Even if design changes or part shortages delay the assembly, the delivery dates are often still fixed. PLC programming tends to happen quite late in the process so the engineers have less time to test and catch any control errors prior to installation. Any manufacturer looking at industrial simulation software should be looking for a solution that allows for earlier programming and validation without any additional work.

Virtual commissioning lets engineers develop control software at the same time as the machine is being built. Once the machine design is clear enough, they can create a digital model and start testing PLC logic with simulated machine behavior. The more accurate the model, the more useful the testing will be. Buyers should check if the software can closely match real mechanical movements and control responses to catch programming mistakes before commissioning.

PLC compatibility can limit simulation’s fit with existing engineering practices. Manufacturers rely on established controller brands and communication standards. Simulators that require major changes to familiar programming environments may add work instead of saving time. Direct communication between virtual equipment and control programs allows engineers to test the same logic used on real machines. Realistic inputs and outputs also help validate automated sequences.

“Nirtec allows automation engineers to begin PLC programming while equipment is still being manufactured, using digital models to test control logic before physical commissioning.”

Creating models also takes time and money. Building every machine part from scratch can use up a lot of engineering hours, especially for small automation teams. Using reusable component libraries and adjustable 3D objects can speed things up, as long as they work for more than just standard setups. Bringing in existing design data can help avoid doing the same work twice. Procurement teams should find out how much expert knowledge is needed to build a good model and if their own engineers can keep it updated when machines change.

Factory changes are a whole different challenge. When a plant shuts down, there’s usually only a short time to install new equipment and any programming mistakes found then will delay restarting. Simulation lets engineers review changes before the equipment is ready for real testing. It also allows them to check control sequences as many times as needed without stopping production. While simulation can’t replace final commissioning, it does cut down on troubleshooting once the plant is available.

The cost of licenses affects how many people can use these tools. If engineering software is expensive, only a few specialists might get access, but lower per-user costs let more automation engineers use it. Price isn’t the only thing to consider. Training needs and how easy it is to get technical help also matter for how fast teams can get up to speed. Manufacturers should also decide if they want to buy software for their own model building or hire a provider to make digital twins from their existing designs.

Nirtec makes the Machines Simulator Suite, which lets engineers build digital twins and test PLC programs with simulated equipment. Its component libraries help create 3D models and both professional and standalone licenses are available for different needs. Nirtec allows automation engineers to begin PLC programming while equipment is still being manufactured, using digital models to test control logic before physical commissioning.

The company also offers digital twin creation services for manufacturers who want to outsource model building, plus software training and educational resources. Regular software updates add new simulation features. This approach is useful for machine builders and automation integrators with tight commissioning schedules, especially those who need easy-to-use simulation tools for smaller teams.