Click here to access the Emulate3D NA08 Press Release entitled, "Emulate3D Controls Testing Increases Your Green Credentials (And Saves You Money)"

Click here to request the Demo3D PLC Controls Testing paper

Demo3D is Uniquely Qualified for PLC Controls Testing

What is Off-line PLC Controls Testing?
Simply put, PLC controlled automation systems consist of a control system and a mechanical system. Often the first time the two meet is during on-site commissioning. The operation of the combined system requires extensive testing, which is complex and difficult to carry out under any circumstances, let alone those encountered at the end of a project, on site. There is pressure from the end user to put the system into production, so it can start to create revenues. There is pressure from the integrator to pass acceptance tests, hand over the project, and move on to the next one. And there is a need to test the logical operation of the finished system.

What are the Benefits of Off-line Controls Testing?
Off-line PLC Controls Testing can take a significant portion of the logical system testing off the critical path, reducing pressure at the commissioning phase, and shortening it. The control system reads inputs and modifies outputs in response. By replacing the actual mechanical material handling system with an accurate model capable of providing the exact same inputs to the control system, several attractive possibilities arise:

• Testing can be started before the actual system exists
• Parallel tests may be made with identical models running simultaneously
• Testing can continue during system build and after handover
• Testing may be more exhaustive than would otherwise be possible
• System ramp time can be significantly reduced
• Operators may be trained prior to system start-up
• Commissioning times become more predictable
• Commissioning costs may be significantly reduced

Why Use Demo3D for Controls Testing?
Off-line controls testing requires a material handling model built with system elements that match the behavior of the real thing. Demo3D is the only industrial modeling system designed to treat product movement realistically, which uniquely qualifies it for this task.

Don't Simulation Products Allow PLC Controls Testing?
If you've ever tried using flow simulation products to carry out controls testing, you'll know that because simulation products reduce reality in order to run fast, they often require much extra work to make them "emulation-ready", significantly reducing the cost-effectiveness of the solution. Although some simulation products allow the accurate modeling of material handling systems, they were designed for a different purpose and are not suitable for PLC controls testing.

How Would You Build a PLC Controls Testing Model?
Functionally exact and highly realistic, Demo3D models can be rapidly assembled from your catalog elements, then connected simply to PLCs (Programmable Logic Controllers) via OPC (Object Linking and Embedding for Process Control) in order to test the logical operation of the control program before the system is built on site.

Can I Reuse Control Components?
Rather than wait until you get on site to fully test the logical operation of the PLC controls, you can connect your PLC control system to the various elements in your Demo3D model, such as photo eyes, motors, diverts and merges, bar code readers, and so on. Because Demo3D elements can be as complex or as simple as you require them to be, catalog elements can be "controls testing ready", with only their I/O to be connected.

Demo3D’s PLC Controls Testing was specifically designed to be quick and easy to use, and it offers the full modeling power of Demo3D Enterprise.

How To Find Out More
To find out more about how PLC Controls Testing could save you time and money at the commissioning phase of your next material handling project:

• Click here to request the Demo3D PLC Controls Testing paper
• Click here to contact your local distributor