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Integrated virtual commissioning an essential activity in the automation engineering process: From virtual commissioning to simulation supported engineering

Production plants within manufacturing and process industries are becoming more and more complex systems. For a safe and demand sufficient production the automation system of a production plant is mission critical. Therefore the correct functioning and engineering of the automation system is essential. Nowadays the use of a virtual commissioning step before deploying the automation software on the real production plant is used more often. Within the virtual commissioning the automation software is tested against a virtual plant model, sufficient to check out the correct functioning of the automation system. Usually virtual commissioning is used as a step at the end of the automation engineering, as proposed by VDI 4499. Within this paper an integrated virtual commissioning is proposed, where the automation software is continuously tested against a virtual plant model during the overall engineering phase. The virtual plant is growing together with the automation software and thus enables simulation supported automation engineering. Benefits of the proposed workflow are that errors can be detected immediately after the implementation and the use of the virtual plant model could be extended to various stages of the engineering workflow.