Pilz Virtualization & Simulation

Engineering Service provides hands-on Pilz Virtualization & Simulation services centered on the Pilz PNOZmulti 2 safety controller and PNOZmulti Configurator toolset. The firm delivers full lifecycle engineering: requirements capture, IEC 61131-3-compliant software design (Structured Text, Function Block, Ladder), deterministic I/O mapping, and simulated runtime validation. Typical engagements use software-in-the-loop (SIL) and hardware-in-the-loop (HIL) approaches to validate safety functions to IEC 61508 and ISO 13849 requirements, while aligning batch and production workflows with ISA-88 and ISA-95 models. The team's virtualization strategy leverages PNOZmulti Configurator's simulation mode alongside industry virtualization platforms such as VMware ESXi and Microsoft Hyper-V for deterministic testbeds, and containerized services where appropriate. Communications are emulated and validated against OPC UA, PROFINET, EtherNet/IP, Modbus TCP and PROFIsafe to ensure correct integration with PLCs, drives, HMIs and safety I/O. Network conditions can be reproduced using traffic shaping and network emulation to validate timeout behavior and fault propagation under realistic conditions. Deliverables include a formal functional specification, I/O list, traceable requirements matrices, automated test protocols, and FAT/SAT documentation. The firm executes virtual commissioning and FAT in its lab or at client sites, using test harnesses that exercise safety-rated logic, interlocks, and emergency stop chains. For SIL assessment and certification support the team prepares safety argumentation, failure modes and effects analyses (FMEA), proof tests, and assists with third-party assessments. Pilz Virtualization & Simulation services emphasize repeatable verification: automated regression test suites, scripted test vectors, and continuous integration pipelines for safety projects. Where required, digital twin models replicate mechanical and process dynamics to validate timing and sequencing against ISA-88 recipes and ISA-95 material flows prior to physical commissioning. On-site commissioning and performance optimization close the loop—fine-tuning PNOZmulti 2 parameters and validating operator procedures under SAT. Training and knowledge transfer are integrated: classroom sessions on Pilz tools, hands-on workshops using the client’s virtual models, and operator maintenance curricula designed to reduce mean-time-to-repair. Long-term support options include remote diagnostics, secure VPN-based access, managed application updates, and on-site service-level agreements. Engineering Service positions itself as a single-source provider capable of delivering Pilz-centered virtualization, safety validation, and operational readiness to ensure safe, on-time plant start-up and lower commissioning risk.