Design, Test & Optimize Before You Build
Emulate your entire automation system in a high-fidelity digital twin — validate control logic, reduce commissioning time, and deploy with confidence.
3D Emulation Environment
Capabilities
Emulate Every Aspect of Your System
From control logic validation to operator training, digital twin emulation transforms how you design, test, and deploy automation.
Virtual Commissioning
Test and validate your control logic against a virtual replica of your production line — before any physical equipment is installed.
Performance Optimization
Identify bottlenecks and optimize throughput using physics-based simulation, driving higher OEE from day one.
Risk-Free Testing
Simulate edge cases, failure modes, and process changes in a safe digital environment — no downtime, no damage.
Training & Scenario Simulation
Train operators on realistic digital replicas and run what-if scenarios to prepare for any production challenge.
Process
Three Steps to Digital Confidence
A streamlined workflow from virtual design to real-world deployment.
STEP 01
Model Your System
Import CAD layouts and define your production environment with drag-and-drop modeling tools. Build an accurate digital replica of conveyors, robots, and stations.
STEP 02
Emulate Control Logic
Connect your PLC programs to the virtual model. Run real controller code against the digital twin and validate behavior in real time.
STEP 03
Deploy with Confidence
Once verified in simulation, take your validated programs straight to the plant floor. Reduce commissioning time and eliminate costly surprises.
Industries
Built for Your Industry
Digital twin emulation delivers measurable value across manufacturing and logistics verticals.
Automotive Manufacturing
- • Validate robotic welding and assembly line sequences virtually
- • Cut commissioning time for new vehicle programs
- • Simulate model changeovers risk-free
Consumer Goods & Packaging
- • Optimize high-speed packaging line throughput
- • Test recipe changeovers in simulation
- • Train operators before line startup
Warehousing & Intralogistics
- • Emulate conveyor sortation and ASRS systems
- • Validate WCS/WES integration before go-live
- • Stress-test peak-volume scenarios digitally
Process Manufacturing
- • Simulate batch control and continuous process flows
- • Verify safety interlocks in a risk-free environment
- • Optimize energy consumption through what-if analysis
For Engineers
Technical Highlights
Enterprise-grade emulation built on industrial standards.
FactoryTalk DesignSuite Integration
Seamless connectivity with the Rockwell FactoryTalk ecosystem for unified engineering workflows.
PLC & Controller Emulation
Run real controller firmware in a virtual environment — test ladder logic, structured text, and function blocks.
Physics-Based Simulation
Accurate kinematics, dynamics, and material flow modeling for true-to-life system behavior.
OT/IT Connectivity
Bridge operational technology and IT systems with standard protocols — OPC UA, EtherNet/IP, and more.
For Rockwell users: Tightly aligned with the FactoryTalk ecosystem — leverage your existing Studio 5000 projects, Logix controllers, and engineering data without conversion overhead.
Proven Outcomes
Results That Speak
30%
Fewer onsite changes
50%
Time saved in testing
40%
Faster commissioning
3×
More scenarios validated
"Digital twin emulation fundamentally changed how we commission new lines. We catch issues weeks earlier and our teams arrive on-site fully prepared."