Virtual commissioning

Up to 30% faster from the idea to the real machine.

The combined development of the mechanical system, electrical system, and automation as a complete system helps machine manufacturers to implement individual, flexible machine concepts in the shortest possible time.

As one of the major components of an efficient engineering process, it ensures a significant reduction of the cost-intensive commissioning time on the machines. This is achieved using efficient simulation tools, which allow to create a virtual image of the machine in no time at all. This supports at an early stage the flexible execution of commissioning tests within a virtual environment.

Moreover, the virtual commissioning system enables early and interdisciplinary verification of development stages, especially between mechanical design and automation.

Virtual commissioning at KAPP NILES

Shortened machine development with Siemens hardware and software

Configuration of the solution

In virtual commissioning, a real control (SINUMERIK 840D sl) communicates directly with a realistic machine model instead of with a real machine (simulation tool SIMIT and the Mechatronics Concept Designer).
The hardware and software complement each other to form a complete solution.



Mechatronics Concept Designer (based on the CAD/CAE/CAM software suite NX of Siemens PLM Software):
fast and efficient design of machine components in conjunction with a realistic simulation of the spatial machine functionality.

SIMIT Simulation Framework:
Simulation of the automation performance and the fieldbus stations.

Simulation Unit
communication interface between the PC-based machine simulation and SINUMERIK 840D sl using PROFINET or PROFIBUS

CNC control SINUMERIK 840D sl
CNC control of the real machine (for the virtual commissioning workstation in the office: SINUMERIK 840D sl VC-Rack)


  • Consistency in the engineering
    from the idea (concept) to commissioning

  • Reduced commissioning time (phase with highest capital costs)
    on the real machine by up to 30%

  • Damage avoided
    on the real machine

  • First validation of the part program
    in a virtual environment


Virtual but palpable

Models of machine tools are really nothing new. However, until now, their main drawback was that they represented reality only poorly or incompletely. A new concept that uses original hardware in key functions produces digital twins.