{"id":7369,"date":"2026-02-10T10:27:02","date_gmt":"2026-02-10T08:27:02","guid":{"rendered":"https:\/\/www.digifai.com\/?p=7369"},"modified":"2026-02-10T10:27:02","modified_gmt":"2026-02-10T08:27:02","slug":"digital-twin-how-simulation-is-revolutionizing-commissioning-and-becoming-an-interactive-3d-hmi","status":"publish","type":"post","link":"https:\/\/www.digifai.com\/en\/neues\/digital-twin-how-simulation-is-revolutionizing-commissioning-and-becoming-an-interactive-3d-hmi\/","title":{"rendered":"Digital twin: How simulation is revolutionizing commissioning and becoming an interactive 3D HMI"},"content":{"rendered":"

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A head start through simulation: The digital twin as a game changer in mechanical engineering<\/span><\/h2>[vc_column_text]Time pressure during commissioning, costly errors on the actual machine, and the growing need for flexibility \u2014 these are the challenges that managers and engineers in modern mechanical engineering face every day. One solution that has evolved from a mere buzzword to a practical technology is the digital twin<\/strong>. igm Robotersysteme AG<\/a>, a leading manufacturer of welding robots for heavy components, impressively demonstrates how digifai’s twin <\/a>simulation software not only perfects virtual commissioning<\/strong> but also optimizes the entire life cycle of a system.[\/vc_column_text]
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The challenge: mastering complexity<\/span><\/h3>[vc_column_text]igm robot systems are highly complex systems. With 6 to 8 axes, often suspended for maximum use of working space, they weld components weighing from 500 kg to 50 tons \u2014 from train components and excavator arms to ship parts.<\/p>\n

\u201cThe control system for our robots is completely digital. This allows for rapid response times, absolute repeatability, and thus consistently high quality,\u201d explains Otto Auer, Head of Control Technology at igm Robotersysteme AG. However, it is precisely this complexity that poses risks during commissioning and subsequent operation. Time-consuming troubleshooting and costly test runs were the order of the day.[\/vc_column_text]

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igm Robotersysteme AG builds welding robots for heavy components. The complex systems are operated intuitively in live 3D HMI.<\/p>\n

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The solution: From simulation to intelligent 3D HMI with twin<\/span><\/h2>[vc_column_text]For around a year now, igm has been using digifai’s twin <\/a>software to create an exact digital twin<\/strong> of its systems. According to Auer, the advantages are fundamental and manifest themselves in three core areas:<\/p>\n

1. Error-free development and virtual commissioning<\/strong><\/p>\n

In the past, control software was developed in parallel with the construction of the machine and could only be tested in a rudimentary manner in advance. The holistic interaction of all components was tested directly at the customer’s site under time pressure \u2014 an approach that can lead to expensive service calls and production downtime.<\/p>\n

With twin<\/a>, this process has changed radically. Engineers now develop and test PLC programs on the virtual model long before the first metal part is manufactured.<\/p>\n