Virtual commissioning at Schaeffler Special Machinery Efficiency and precision in machine development
Virtual commissioning is an integral part of Schaeffler Special Machinery's engineering process. Using simulation software such as fe.screen-sim, our teams can test machines and systems digitally, flexibly and from any location at an early stage of the project. The aim is to validate control software and complex processes in advance, as well as simulate critical states risk-free. The fe.screen-sim software significantly supports us by enabling parallel process development, shortening development times, and noticeably improving the quality of our special machines.
Diverse test scenarios for maximum functional reliability
At Schaeffler Special Machinery, we use virtual commissioning specifically to validate control and regulation strategies at an early stage and to comprehensively ensure machine functions - for example for gearboxes, axle systems, battery modules and packs or even for chainsaws or toothbrushes. The simulation of complex motion sequences, load changes or temperature curves allows us to analyze the behavior of components under realistic conditions - long before the first screw is installed. This allows us to simulate a wide range of operating scenarios, identify critical limits and reliably evaluate system behavior. This increases safety and quality - regardless of the industry or application.
Simultaneous engineering in demanding projects
The increasing complexity of our projects requires efficient, networked processes, especially when product development and machine realisation occur simultaneously. This is crucial in so-called 'simultaneous engineering'. With fe.screen-sim, international teams can work on a digital model in parallel. Our software programmers can start working while procurement and assembly are still in progress. The multi-user capability enables the creation and testing of the SPS at an early stage.
This is a significant advantage, particularly in simultaneous engineering. System designs are created in parallel with product development. This allows us to conduct thorough testing and reduces the workload during critical project phases. For mechanical engineering, this means shorter project lead times and higher quality. Despite all the advances in virtual commissioning, physical commissioning remains important, even though up to 95% of tasks can now be mapped digitally.
Networked development - ready for global use
A striking example of the effectiveness of virtual commissioning is an international project by Schaeffler Special Machinery, in which development teams in Germany and China collaborated on a digital plant model simultaneously. This was made possible by setting up a digital twin at an early stage of the project.
Thanks to the multi-user functionality and clear separation between the simulation core and user client, all teams were able to access the virtual environment in real time to make adjustments and evaluate test results. Language and time differences were irrelevant. Digital collaboration enabled asynchronous work on a central model.
Not only could commissioning begin earlier, it could also be completed with a higher degree of maturity. End-to-end simulation facilitates international collaboration, accelerates processes, and improves quality — providing a real competitive advantage in global manufacturing.
Prospects for virtual commissioning at Schaeffler Special Machinery
Virtual commissioning is a key aspect of Schaeffler Special Machinery's future viability. It enables us to work faster and more flexibly, while using fewer resources and maintaining consistently high quality. By using virtual commissioning strategically, we can test processes earlier, minimize risks, and significantly improve the efficiency of the project process. This enables us to develop modern, high-performance production solutions that are tailored to our customers' requirements and the challenges of an increasingly digital industry.
May 2025
