NexaTwin

Software Validation in the Digital Twin for Machines and Systems

With NexaTwin Software Validation, you can test PLC logic, plant functions, and fault conditions even before actual commissioning. Processes can be tested systematically in the digital twin, problems identified early, and workflows efficiently coordinated together.

Overview

Early software testing for faster and safer commissioning

Software validation makes functions and processes in the digital twin systematically verifiable. Control logic, process steps, and reactions to defined error cases can be tested early, even before the real plant is fully built or commissioned. This makes virtual commissioning a reliable preliminary stage to real commissioning. Problems are identified earlier, corrections can be implemented more precisely, and the later on-site phase proceeds in a more structured and efficient manner.

Core Functions

Functions of Software Validation at a Glance

Optimize

Test control logic early

PLC-controlled system functions can be specifically tested in the digital twin and optimized even before actual commissioning.

Control

Structurally validate process flows

Sequences, functions, and plant responses can be tested and evaluated in the model under controlled conditions.

Reduce

Safely analyze and resolve errors

Disruptions and problematic conditions are detected early in the digital twin, analyzed transparently, and rectified before real-world commissioning.

Stress testing

Check complex tracking logic with PLC

Component tracking and complex logic can also be reliably tested in the digital twin together with the PLC.

Flexible

Compatibility with various control systems

NexaTwin includes full interface compatibility for control systems such as Siemens, Rockwell or Beckhoff TwinCat, as well as robot control systems like KUKA, Fanuc or ABB.

Your Benefits

Why Software Validation Pays Off in Projects

With an attached control system, processes, signals, and software functions are realistically tested in the digital twin.

Accelerate

Significantly shorten commissioning time

Control logic, sequences, and error cases are already tested in the digital twin. This reduces on-site iterations and speeds up real commissioning.

Identify

Detect and fix errors earlier

Problems in PLC logic and plant sequences can be identified and specifically corrected even before deployment on the construction site.

Repeat

Execute tests reproducibly

Functions, sequences, and error cases can be tested in a structured manner and repeated under the same conditions at any time.

Focus

Coordinate software efficiently together

Programming, mechanical engineering, and end-users can jointly review processes and functions directly on the digital twin and release them faster.

Reduce

More safety before using construction sites

The software is validated under practical conditions before actual commissioning. This reduces uncertainties, rework, and coordination efforts.

Typical Applications

Typical Applications for Software Validation

Software validation is particularly suitable for projects where PLC and robot logic, processes, and special cases need to be validated early.

Examples:

Testing of PLC or robot-controlled machine and plant functions
Validation of process flows and sequences prior to actual commissioning
Examination and analysis of defined error cases in the digital twin
Test complex component tracking and tracking logic with the PLC
Joint release of software features with Mechanical Engineering, customer, and commissioning team

User

For whom software validation is particularly relevant

This module is particularly interesting for:

PLC Programmer / Commissioning Engineer
Automation Engineers
Machinery and plant manufacturers
Project Manager for Automation Projects
Technical Service Providers
Customers who want to safely approve functions and processes before real commissioning

Categorization in NexaTwin

Software Validation as a Logical Step After Layout and Mechanics

While the Layout Manager primarily creates structure, orientation, and visual clarity and Mechanic Validation ensures real movements, collisions, and clearances, Software Validation focuses on the PLC and robot logic and the plant's sequence of operations. Thus, this module represents the next crucial step in virtual commissioning: not only the layout and mechanics are pre-checked, but also the actual control function. On this basis, further modules like LiveTwin or HMI can later be more precisely integrated into real operations.

Nächster Schritt

Secure software logic early in the digital twin

Learn how to test control logic, process flows, and error cases early with NexaTwin Software Validation and prepare your commissioning much more efficiently.