How do you validate control logic before your machine is built? 🛠️ With iPhysics by our partner machineering, users can simulate mechatronic systems in real time and connect their PLCnext Control directly to the simulation. This allows control programs to be tested on the digital model early in the development process. What makes this setup useful? 🔍 Better system understanding: Visualize machine behavior before hardware is available 🧪 Risk reduction: Identify and fix logic errors before commissioning 👥 Cross-disciplinary collaboration: Mechanical and automation engineers work on one model 🔁 Efficient iteration: Adjust control strategies and immediately see the impact This setup helps teams reduce errors, shorten development cycles and improve system understanding – especially in complex automation projects. #plcnext #iamplcnext #PLCnextCommunity #simulation #software #machineering #partner

🚀 Hands-on Practice with Siemens Process Simulate (PS) & Virtual Commissioning🚀 I recently deep-dived into Process Simulate software and practiced end-to-end workflows that bridge virtual studies, PLC logic, and HMI simulation. 🔹 Key Focus Areas Covered: 1️⃣ Opening and managing studies – selecting libraries, working with different operating modes. 2️⃣ Graphics manipulation – customizing keyboard, mouse, ribbon, navigation cube, and viewer tools. 3️⃣ Exploring tabs – File, Home, View, Modeling, Robot, and Control – and their practical use. 4️⃣ Object modeling & logic blocks – creating logic from poses, setting device scope. 5️⃣ Signal engineering – creating, filtering, mapping, and exporting signals. 6️⃣ Tag management – importing PLC tags, linking them to PS logic blocks, and mapping via Excel. 7️⃣ Simulation panel – monitoring, forcing signals, and testing tool behavior. 🔹 Integration Practice (Optional Add-ons): * Studio 5000 & TIA portal PLC code creation with hardware I/O mapping and tag logic. * HMI screen development for manual clamp/pin operations. * FT Logix Echo setup – adding chassis/controller, downloading PLC backup, and going online. * PLC Sim Adv- downloading PLC backup, and going online. 🔹 Final Simulation Exercise: Created a Virtual Commissioning environment to test clamp/pin, Robot Weld, Tip dress movements, Turntable manual operations by linking: ✔ PLC code ✔ HMI interface ✔ PS study with logic blocks & signals ✔ Studio 5000, FT view ME & PS using FT Logix Echo controller connection ✔ TIA portal using PLC SIM Adv connection This practice gave me a clear understanding of how Digital Twin and VC workflows come together, from study setup → signal mapping → PLC/HMI integration → full simulation testing. Excited to keep building on this foundation and apply it to real-world projects! ✨ #Siemens #ProcessSimulate #VirtualCommissioning #DigitalTwin #RockwellAutomation #FTLogixEcho #Studio5000 #TIAPortal #PLCSIMADV #FTView #Industry4.0 #Automation #Robotics

How do you validate control logic before your machine is built? 🛠️ With iPhysics by our partner machineering GmbH & Co. KG , users can simulate mechatronic systems in real time and connect their PLCnext Control directly to the simulation. This allows control programs to be tested on the digital model early in the development process. What makes this setup useful? 🔍 Better system understanding: Visualize machine behavior before hardware is available 🧪 Risk reduction: Identify and fix logic errors before commissioning 👥 Cross-disciplinary collaboration: Mechanical and automation engineers work on one model 🔁 Efficient iteration: Adjust control strategies and immediately see the impact This setup helps teams reduce errors, shorten development cycles and improve system understanding – especially in complex automation projects. #plcnext #iamplcnext #PLCnextCommunity #simulation #software #machineering #partner

🚀 Innovation in Industrial Automation with ICAP At ICAP, we continue to drive excellence in automation through advanced simulation ⚙️ and control solutions 🎛️. 🤖 We recently developed a comprehensive ABB robot simulation in RobotStudio, including conveyor 🛠️, gripper ✋, and RAPID programming 💻, fully integrated with PLC 🔌, TIA Portal, NX, and HMI 📊. ✨ This project allowed us to: ✅ Optimize processes 🔄 ✅ Validate workstations before physical implementation 🏭 ✅ Ensure secure & efficient system integration 🔐⚡ ✅ Deliver intuitive HMI interfaces for end users 👨💻👩💻 #IndustrialAutomation #RobotStudio #ABB #PLC #TIAportal #HMI #NX #ICAP #Innovation

✨ Mini Project using Factory & TIA This project shows an assembly line that automatically combines two parts. I built the project using: 🔹 PLC S7-300 programming in TIA Portal 🔹 3D industrial simulation with Factory I/O The goal was to simulate industrial control systems and understand how production lines (conveyors, sensors, actuators) operate in a realistic environment. #HAConsultingGroup #IndustrialAutomation #SiemensPLC #MechatronicsEngineering

✨ Mini Project using Factory I/O & TIA Portal This project demonstrates a Pick and Place system applied on a conveyor with sensors and actuators. 📌 How it works: Two boxes (small and large) move on the conveyor. The sensors detect the size of each box. The actuators pick the small box and place it on a second conveyor. The large box continues its path on the main conveyor. 🛠️ I built the project using: 🔹 PLC programming in TIA Portal 🔹 3D industrial simulation with Factory I/O 🎯 The goal was to simulate industrial control systems and understand how conveyors, sensors, and actuators can be used in real-world sorting and handling applications. #HAConsultingGroup #IndustrialAutomation #SiemensPLC #Communction Engineering #FactoryIO

🤔 Have you ever wondered how machining can be fully automated by integrating CNC machines 🛠️, industrial robots 🤖, and automated production lines 📦? Here’s a simplified example demonstrating exactly that 👇 Using Factory IO 🖥️ for simulation and Siemens TIA Portal⚙️ for PLC programming, I created a two machining center cells where: 🔹 The machining center and robot states are used as inputs to the master PLC . 🔹 The PLC decides when the system starts , stops , loads , and unloads . 🔹 Every action is synchronized to ensure smooth and safe operation ✅ This integration shows how modern manufacturing achieves: 🚀 Higher productivity 🤝 Seamless communication between machines 🧠 Smarter decision-making at the control level While this is just a simulation, the same logic applies to real-world Industry 4.0 environments 🌍, where CNCs 🛠️, robots 🤖, and automation lines 📦 work together under centralized PLC control. 🎥 Check out the video below to see the process in action! #Automation #PLC #TIAportal #FactoryIO #Industry #SmartManufacturing #DigitalTwin #CNC #Robotics

HedraCAM V4 – Virtual Commissioning & Controller Integration HedraCAM V4 takes virtual commissioning to the next level—seamlessly connecting software intelligence with industrial hardware for faster, safer, and more efficient deployment. 🔌 Direct Hardware & Virtual Controller Connectivity Connect directly to physical controllers or run virtual debugging for both robotic and NC (Numerical Control) systems. Integrate effortlessly with PLC systems for both direct connection and virtual testing. 📡 Comprehensive Sensor & Vision Integration Supports real-time communication with a wide range of industrial hardware, including vision systems and other advanced sensors—bridging the gap between simulation and shop-floor reality. 🤝 Interoperability with Leading Global Brands As demonstrated in the video, HedraCAM V4 achieves full interoperability with: Siemens and Omron PLCs FANUC robot controller virtual machines FANUC NC controller virtual machines Nabtesco controller virtual machines Aubo controller virtual machines 🧠 Test, Validate, Deploy—All in One Platform Simulate robotic motion, validate NC programs, and debug PLC logic in a risk-free virtual environment before going live—reducing downtime and accelerating integration. 🌐 Engineered for Global Smart Manufacturing Whether for automotive, aerospace, electronics, or heavy industry, HedraCAM V4 delivers universal compatibility, precision control, and future-ready scalability. More groundbreaking features are on the way—stay tuned!

Why a Digital Twin is Non-Negotiable for Commissioning That moment of truth when control logic meets physical equipment is fraught with risk. Unexpected bugs, safety shutdowns, costly delays. But what if you could run the entire commissioning process—debugging, tuning, training—months before power-on? The answer: A Digital Twin. It's not just a 3D model. It's a dynamic virtual replica of your system (machine, line, or plant) connected to your actual PLC/DCS code. A high-fidelity sandbox for your control logic. Why is it essential pre-commissioning? ✅ Eliminate Risk & Downtime: A sequencing error causes a virtual tank to overflow on a screen, not on your factory floor. Fix it in minutes, not days. ✅ Compress Schedules: While mechanics install hardware, automation engineers test and debug the entire system in simulation. Slash weeks off your critical path. ✅ Perfect Control Loops: Aggressively tune PIDs for a furnace or reactor without impacting production, quality, or safety. Achieve optimal performance before startup. ✅ Train Operators Safely: Practice startups, shutdowns, and emergencies like pump failures in a consequence-free environment. Build confidence and muscle memory. The Bottom Line: A Digital Twin isn't a luxury. It's the key to transforming commissioning from a high-stakes gamble into a predictable, efficient, and safe process. It's not about doing things faster; it's about doing them right the first time. What's been your experience with Digital Twins? Share below. Oktay ÖZTOP I&C Suprvisor #DigitalTwin #IndustrialAutomation #ProcessAutomation #Commissioning #Simulation #IIoT #Industry40 #Engineering #RiskManagement

🚀 From Design to Reality – Simulate Smarter with Mitsubishi Electric Before the first cable is connected or the first robot is moved, every detail can already be tested, optimized, and validated. With the Mitsubishi Electric software ecosystem, you can bring your automation projects to life virtually – saving time, reducing risks, and boosting efficiency: ✅ iQ Works2 – integrated engineering suite for PLC, motion, HMI and network configuration. ✅ RT Toolbox3 – advanced robot simulation, programming and optimization tool. ! Including simplified Visual Programming for industrial robots. ✅ MELSOFT Gemini – 3D digital twin for production lines, machines and complete cells. Together, they create a seamless environment where: 🔹 Mechanical, electrical, and control teams collaborate on the same digital model. 🔹 Robot trajectories and machine cycles are optimized before installation. 🔹 Bottlenecks are identified early – not during production. 🔹 Operators and engineers can be trained virtually. 💡 The result? Faster commissioning, lower costs, and higher quality from day one. At Mitsubishi Electric, we believe simulation isn’t just an add-on – it’s the foundation of smarter engineering. #DigitalTwin #Simulation #Automation #Robotics #MitsubishiElectric