Tobias Willer
+49 2664 25 242-0

Would you like to commission your automated system quickly and reliably? We make it possible with a test simulation.

Our world is constantly changing and is becoming increasingly digitalised. With the help of the digital twin, comprehensive abstraction and modelling of systems and machines is possible. The object is digitally represented, recorded, modelled and simulated. The digital twin shows the complete machine or system virtually 1-to-1 and simulates your individual processes. In combination with automation, predictions of results can be made, resulting in beter business processes, lower risks and increased operational efficiency. The digital twin makes it easier to overcome business challenges by optimising the workflow. 

Even before a machine is actually commissioned, we can simulate all of its functions and thus identify faulty designs at an early stage. Virtual prototyping allows us to recognise in the design phase whether processes will function as planned. We virtually simulate the exact processes that will later take place in reality. 

We have published an advertorial on this topic in the Handelsblatt. 

blue automation has many years of experience with software for creating digital twins such as the Mechatronics Concept Designer. As an official Siemens partner, we can also offer our customers suitable software licences if required, e.g. for playing back the files. We are also experts in digital behaviour models of system components (FMU) and create these as building blocks for the digital twin. This enables us to cover the entire spectrum and ensure that the digital twin delivers concrete added value for our customers.

Explanatory video with the digital twin

The digital twin - how to design and test machines safely and efficiently!

Thomas Grahl CEO of blue automation at the Siemens stand at the SPS trade fai

Success model simulation: pre-simulated efficiently automated

Siemens Solution Partner blue automation GmbH

Virtual comissioning

During virtual commissioning, a simulation of the future system is created that contains its motion sequences. Based on the simulation, all planning data can now be imported, tested and changed virtually on the computer. The programmers can test the programme they have writen and see whether the system can run without errors in terms of both software and hardware. There are various levels within the virtual image of a digital twin. 

Man looking at two PC screens

Companies in the manufacturing industry in particular benefit from using the digital twin. Results that support process optimisation can be achieved right from the start of using the digital twin without major hardware efforts. The creation of a virtual image contributes to a beter understanding of the operation of the plant. This has the advantage that processes or products can be extensively optimised within the company, even for the future. 

When it comes to more complex systems within different production processes, the digital twin finds its optimal place of use, because the larger the system, the more sensible it is to use a digital twin. Efficiency can be increased with the digital twin, especially in the production of large quantities. Employees can understand the system even beter and thus recognise problems earlier and develop improved processes. This saves time in the future and minimises the risk of problems in production. 

Digital Twin

Engineering phase:


Mechanical design provides 3D data of the planned machine, which is then imported into the MCD and is available for further processing.


By adding the physical properties, the movements, behaviour and interfaces of all actuators and sensors are mapped. 


Running and testing all necessary movements to check mechanical limits and validate the machine sequence. 


Programmes developed in parallel are then tested and validated with the twin. This is where the virtual commissioning takes place.

Further utilisation phase:


Twin is available with PLC, operating elements and 3D data. This means that new and inexperienced operating personnel can be trained on it without jeopardising the real system through incorrect operation. Various error scenarios and their solutions can be practised.


System was developed with Zwilling and is running. The system is to be converted / extended after 5 years. You can then plan and implement the conversion on the twin, adapt the so􀅌ware and test the whole thing. Only then can the real system be converted, thus minimising the downtime of the real system during the conversion. 


System beautifully illustrated and depicted. Can also be used for advertising purposes. 

The mechanical 3D design of the system is kinematised and provided with physical properties. The programmer can test the PLC programme he has created on the digital twin of the real system. In addition, planned extensions to existing systems can be simulated virtually without affecting the physical system. 

By connecting control systems with the NX Mechatronics Concept Designer, it is possible to carry out virtual commissioning of existing programmes. 


  • Risk minimisation by safeguarding the mechanical design
  • Faster commissioning of automated systems
  • Higher quality of software programmes
  • Early training of operating personnel on the digital twin
  • Saving time, costs and resources
  • Improved product quality
  • Shorter time to market
  • Improving the agility and resilience of the supply chain
  • Sustainability within the value chain
  • Increase in operational efficiency
  • Increase in productivity


Siemens MCD Logo

Are you interested?
Please feel free to contact us.


blue automation GmbH
Hauptstraße 67
56477 Rennerod

+49 2664 25 242-0