Digital Engineering How Simulation Reduces Development Risks Early

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Errors during commissioning cost time and money—but they can often be avoided during development. Simulations make it possible to test machines virtually before a prototype is created. How designers use this to reduce risks and make projects safer.

If errors only occur at the test bench or during commissioning, it quickly becomes expensive in mechanical and plant engineering. Deadlines come under pressure, test capacities are blocked, and changes extend into the late project phases. At the same time, the complexity of machines is increasing: more software, more sensors, and higher requirements for automation and networking. For designers and developers, this means that decisions need to be secured much earlier—often long before a prototype exists. This is where simulation comes into play, as is well known: it allows machines and systems to be represented virtually and functions to be realistically tested in the early stages of development. Mechanics, electronics, and software can thus be developed and validated together.