System Emulation

The Next Level in Warehouse Visualization

In the world of automated and material handling systems, time is the key to success. Faster implementation means being able to reap the benefits of modernized systems earlier. Cutting edge technology and software tools are making that happen. Bastian Solutions industrial controls uses emulation software to create, not only a visual representation of systems, but a “digital twin” that allows for in-depth access before installation begins. 

Functioning as a virtual copy, Bastian Solutions’ industrial controls engineers leverage this 3D virtual representation and populate it real sequences through the controls PLC (programmable logic controller). This allows for faster, more thorough testing, validation and training for a more successful automation system.

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Visualize Material Handling & Automation System Challenges

As material handling and automation projects are developed, visual representations can be created at different stages to view, validate, test and confirm automation systems.  Doing so helps to:

  • Test systems with real data and sequencing
  • Confirm ability to meet project objectives
  • Mitigate unforeseen challenges
  • Expedite on-site installation and go live
  • Avoid unexpected costs
  • Reduce long, complicated training

What is Emulation?

Unlike renderings, animations and simulations that are often developed in the consulting or design system phase, emulations help fine tune programming before installation and system go-live, speeding up the commissioning process and helping to keep overhead costs down. Pre-installation, industrial controls designers utilize emulations to connect the PLC and real-data sequences for accurate inputs like dimensions, speed and more.

Controls Emulation Process & Considerations


The controls emulation process starts when a project is released for build. Using Emulate3D, Bastian Solutions controls engineers use real input and sequences from the PLC connection to view, pause, analyze, review and adjust the way that the technology, like conveyors, will operate in the warehouse.

Throughout the process, the following are some of the parameters that can be reviewed:

  • Throughput speed
  • Motors and sensors
  • Dimensions for hardware, products or materials handled

We can calculate and refine throughput rates, identify bottlenecks, and smooth out start up details. The final step in the process is to mate the digital twin or emulation with actual machine code, running on the same PLC that will be installed onsite.

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