Here, NORD DRIVESYSTEMS describes how virtual commissioning, using techniques such as advanced simulation models and digital twins, can mitigate complexities and risks inherent in process technology projects.
Process technology projects are rarely simple; they’re intricate, interdependent, and full of variables that can shift unexpectedly. Coordinating equipment specifications, predicting system behaviour and ensuring compatibility across components all introduce risk. Even minor oversights can cascade into delays and added cost. Fortunately, modern engineering tools are reducing that burden. Advanced simulation models, intelligent drive technologies and digital twins now give engineering teams clearer insight, greater control and more confidence as they manage these demanding projects.
NORD DRIVESYSTEMS has expanded its support for system development by offering digital twins based on customer-specific myNORD configurations. Engineers can request simulation models of fully customised drive systems, enabling them to verify early in the planning phase whether a selected drive concept is suitable for their application. This virtual commissioning capability significantly shortens project timelines, even for complex installations.
Since the introduction of the FMI (Functional Mock‑up Interface) standard in 2010, simulation models have become increasingly common in system planning. NORD has long used data‑driven simulations to develop its own components and drive solutions. Now, the company is applying this expertise to help customers improve efficiency and system availability from the outset by providing digital twins as a new virtual commissioning service.
Configuration is straightforward. Users specify their required drive systems or components through the myNORD customer portal, selecting performance parameters, mounting options and outputs. They can then request a simulation model for the configured system. This capability was developed in partnership with Machineering, a Munich‑based specialist in virtual commissioning.
The primary advantage of NORD’s digital twins is the dramatically accelerated path from design to commissioning. Simulation models can be integrated into a virtual representation of the customer’s system, allowing extensive testing of drive configurations. Adjustments can be made quickly using simulation data, and potential errors can be identified and resolved early, preventing costly issues later. Once validated, NORD manufactures and delivers the drive system. Because the drives have already been integrated into the system control virtually, on‑site commissioning can be completed in a fraction of the usual time. Overall, the process from configuration to commissioning can be reduced from several months to just a few weeks.
Virtual commissioning is especially valuable for demanding applications. NORD has initially focused on components critical to automated production, including high‑efficiency IE5+ and IE4 motors, matching gear units, and frequency inverters. These lines are already available virtually, with additional product lines to follow.
