AMD Automation leverages digital twin technology and advanced simulation software to design, validate, and optimize your automation systems before physical construction begins. This Industry 4.0 approach reduces project risk, accelerates deployment, and enables continuous improvement throughout the system lifecycle.
What is a Digital Twin?
A digital twin is a virtual replica of your physical automation system that mirrors real-world behavior in a simulated environment. Our digital twins include:
- 3D mechanical models of robots, fixtures, and equipment
- Motion simulation with accurate cycle times and trajectories
- PLC logic simulation to validate control sequences
- Sensor and I/O mapping for complete system behavior
- Real-time data synchronization for operational optimization
Benefits of Virtual Commissioning
Reduce Project Risk
Test and validate your automation concept before cutting metal. Virtual commissioning identifies: - Robot reach and interference issues - Cycle time optimization opportunities - Safety system coverage gaps - Control logic errors
Accelerate Time-to-Production
- Develop robot programs offline while equipment is being built
- Validate PLC code before on-site installation
- Train operators before the system arrives
- Reduce on-site commissioning time by 30-50%
Lower Total Cost
- Catch design errors early when changes are inexpensive
- Reduce physical prototyping requirements
- Minimize costly on-site modifications
- Optimize cycle times for maximum throughput
Simulation Software Platforms
We work with industry-leading simulation tools:
Robot Simulation
- FANUC Roboguide - Complete FANUC robot simulation with virtual teach pendant
- ABB RobotStudio - Full ABB robot programming and simulation environment
- KUKA Sim - KUKA robot offline programming and validation
- Yaskawa MotoSim - Motoman robot simulation software
Process Simulation
- Visual Components - 3D manufacturing simulation platform
- Tecnomatix Process Simulate - Siemens digital manufacturing suite
- Delmia - Dassault Systemes robotics simulation
- RoboDK - Universal robot programming and simulation
PLC Simulation
- RSLogix Emulate - Allen-Bradley PLC simulation
- PLCSIM Advanced - Siemens S7 virtual controller
- GX Simulator - Mitsubishi PLC simulation
Digital Twin Applications
New System Design & Validation
Before building your robotic cell or welding system, we create a complete digital twin to:
- Validate robot selection and placement
- Optimize cell layout and floor space
- Verify reach, payload, and cycle time
- Test safety system coverage
- Develop and debug robot programs
Offline Robot Programming (OLP)
Generate production-ready robot programs without stopping production:
- Create new programs for product variants
- Optimize existing paths for cycle time reduction
- Test program changes in simulation
- Download validated programs to production robots
Process Optimization
Use digital twin data to continuously improve:
- Identify bottlenecks and balance cycle times
- Simulate "what-if" scenarios for throughput improvement
- Plan maintenance windows with production impact analysis
- Validate changeover procedures
Operator Training
Train operators in a risk-free virtual environment:
- Practice normal operations and procedures
- Simulate fault conditions and recovery
- Learn troubleshooting without production impact
- Validate competency before live operation
Virtual Commissioning Process
Phase 1: Model Development
We build accurate 3D models of all system components: - Import CAD data from your design team - Create kinematic models of robots and motion axes - Define gripper and tooling geometry - Model sensors, conveyors, and safety devices
Phase 2: Program Development
Develop and validate all automation programs: - Robot motion programs and paths - PLC ladder logic and function blocks - HMI screens and operator interfaces - Safety PLC programming
Phase 3: Integration Testing
Test complete system behavior in simulation: - Run full production cycles - Test all operating modes (auto, manual, maintenance) - Validate safety system response - Verify error handling and recovery
Phase 4: Validation & Handoff
Document and transfer validated programs: - Create program backup and documentation - Generate cycle time reports - Provide simulation models for future use - Support physical commissioning
Industries Leveraging Digital Twins
Digital twin technology delivers value across industries including automotive production validation, medical device process documentation, aerospace program development, and electronics assembly optimization.
Integration with Physical Systems
Our digital twins don't stop at commissioning. Connect your digital twin to production systems for:
- Real-time monitoring - Mirror production data in the digital environment
- Predictive maintenance - Simulate wear and predict failures
- Continuous improvement - Test changes virtually before implementation
- Remote support - Troubleshoot issues using the digital model
Ready to leverage digital twin technology? Contact us to discuss how virtual commissioning can accelerate your next automation project.