Simulation Modes

Three Engines, One Platform

Choose the right simulation fidelity for each phase of your project. From quick capacity studies to full virtual commissioning.

Flow
Co-Sim
Hybrid
Simulation Speed
⚡⚡⚡
⚡
⚡⚡
Signal Accuracy
●○○
●●●
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PLC Required
No
PLCSimAdv
Optional
Best For
Planning
Commissioning
Validation
MODE A
🌊

Flow Simulation

Fast Material Flow Analysis

Optimize throughput and capacity with discrete event simulation. Perfect for early-stage planning and what-if analysis.

Key Features

DES Engine

High-performance discrete event simulation engine

Physics-Derived Timing

Accurate cycle times based on real machine parameters

Monte Carlo Sweeps

Run thousands of scenarios to find optimal configurations

KPI Dashboard

Real-time throughput, OEE, and utilization metrics

Batch Simulations

Simulate 365 days of production in minutes

Failure Modeling

MTBF/MTTR stochastic breakdown simulation

Use Cases

  • Capacity planning for new lines
  • Buffer size optimization
  • Shift schedule analysis
  • Investment justification
MODE B
🔌

Co-Simulation

Hardware-in-the-Loop Testing

Connect to real PLCs for signal-level virtual commissioning. Validate control logic before deployment.

Key Features

TIA Portal Import

Import projects and tags via Openness API

Live Signal Monitor

Watch I/O states update in real-time

I/O Forcing

Override signals for testing edge cases

OPC UA Connectivity

Connect to PLCs and devices via OPC UA

PROFINET Integration

Native PROFINET fieldbus support

Signal Tracing

Record and replay signal sequences

Use Cases

  • PLC code validation
  • HMI screen testing
  • Safety system verification
  • Commissioning preparation
MODE C
⚡

Hybrid Engine

Best of Both Worlds

Combine flow simulation speed with PLC accuracy. Switch between modes based on what you need to test.

Key Features

Signal-Flow Bridge

Seamless data exchange between engines

PLC Overhead Analysis

Measure control system impact on throughput

Concurrent Co-Sim

Test multiple stations with PLCs simultaneously

Regression Baselines

Track performance changes across versions

Test Generation

Auto-generate test scripts from simulations

Time-Domain Switching

Hot-swap between flow and co-sim modes

Use Cases

  • Full line validation
  • Performance regression testing
  • Change impact analysis
  • Continuous integration

Not Sure Which Mode to Use?

Start with Flow Simulation for planning, then move to Co-Simulation for commissioning.

Compare Plans
FAQ

Simulation Mode Questions

Which simulation mode should teams start with?

Most teams start with Flow Simulation for quick capacity and bottleneck analysis, then move to Co-Simulation or Hybrid mode for detailed control validation.

Do all projects require PLC co-simulation?

No. PLC co-simulation is best when virtual commissioning and control logic testing are needed. Planning-only studies can often begin with flow simulation.

Can modes be combined in one project?

Yes. Hybrid workflows are designed to combine fast flow-level analysis with PLC-accurate behavior where higher fidelity is required.

How do simulation modes support commissioning risk reduction?

By validating performance and control interactions before deployment, teams can reduce commissioning surprises and shorten ramp-up.