Virtual commissioning and digital twins: a new era for motion-control programming

In factories, motion control systems are more complex than ever. Multi-axis machines, integrated robotics and tight production schedules leave little room for trial and error. For decades, programmers have had to wait until the first machine was assembled to test their code, often discovering issues once it was most costly to fix them.

Now, many industrial control programming environments are offering digital-twin capabilities that are changing that equation. By creating a virtual replica of a machine in software that can be tested and refined before the hardware even exists, programmers gain a safer, faster and more collaborative way to develop motion control applications.

What is a digital twin in motion control?

The simple definition of a digital twin is a virtual replica of a physical machine or motion system, synchronized with control logic. Unlike a basic simulation, the twin is connected to the actual control logic, exchanging I/O, status signals and motion commands in real time. It doesn’t just look like the machine; it behaves like it, using accurate kinematics, physics models and live feedback loops. Because it mirrors the actual machine behavior, programmers can run the same PLC or motion code against the twin as they will on the factory floor. It is useful for full virtual commissioning, testing safety configurations, debugging logic, operator and maintenance training and lifecycle support.

Think of the difference between a simulation and a digital twin like aviation simulators. A basic simulation is like a flight demo on a screen: you can see how the plane should move through the sky, and you can test scenarios visually, but your inputs don’t actually drive the aircraft model in real time. A digital twin, on the other hand, is more like a true flight simulator that is wired to the same avionics software the real aircraft uses. Every control input you make—throttle, rudder or flap adjustment—is processed through the actual control logic and reflected instantly in the simulated plane’s behavior. One is a picture of motion; the other is a living replica you can virtually fly.

Advantages for motion programmers

Because the twin machine is virtual, the programmer gets to enjoy risk-free testing to detect collisions, over-travel and logic errors without damaging any hardware. As a matter of fact, code debugging can begin in parallel with the machine build, shortening commissioning time. The larger development team also gets deeper insights into the dynamics the machine will experience. They will be able to see how payloads, inertia or compliance affect motion, speeds and latencies. Tuning and trajectories can be optimized before hardware is even purchased, avoiding unnecessary rework in the control code. All this leads to the first power-up being smoother, with fewer unknowns.

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The impact on the commissioning process

The traditional method of machine development has always been some variation on this theme: wait for hardware, go through long debug cycles and then expect surprises at the end requiring changes to hardware, programming, and interface aspects. Now, because the virtual model can be shared with the entire cross-discipline team, the model helps connect programmers, mechanical engineers and operators to design, evaluate, test and correct the model prior to the machine being finished.

Changes to the hardware specifications can be made prior to the first purchase order being written. With simulation through a digital twin, early code can be tested at any point, reducing downtime and making commissioning much less stressful.

Beyond commissioning: the lifecycle benefits

The same qualities that enable streamlined commissioning of a new machine also translate into incremental or major improvements in the future, resulting in less risky changes made to installed machines. Hardware changes due to supply chain disruptions, obsolescence or improved device design can be made to the twin and evaluated without taking down running equipment. Similarly, validation tweaks, data logging, product traceability or late-stage improvements can be tested off-line, again reducing downtime by proving changes virtually prior to bringing a machine or line down to test a change or improvement.

After the machine has been commissioned, the long-term use of the digital twin can continue as a training and support tool. The twin can provide realistic operator training without occupying production equipment, and it can also be useful for troubleshooting issues later by replicating problems in the twin before sending technicians to work on the actual machine.

As motion systems grow in sophistication, digital twins are quickly shifting from nice-to-have tools to essential parts of the engineering workflow. They not only shorten commissioning time and reduce risk, but also provide long-term value in training, troubleshooting and continuous optimization. For motion programmers, embracing simulation means moving beyond reactive problem solving toward proactive, model-driven development. In an industry where every hour of downtime counts, the ability to test, validate and refine in the virtual world before deploying to the real one is becoming the new standard of excellence.