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Automation Simulation and Digital Twin Software

Maximize your robotics investment with unmatched precision

Integrating advanced robotics can be a costly leap. Digital Twin Studio^® ensures your investment pays off by validating every detail of your automation systems before they hit the floor, and keeps them operating at maximum efficiency throughout their entire lifecycle.

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Digital Twin Studio Methodology: 4 steps to success

Automation integration software should be simple. Digital Twin Studio^® takes a unique approach to guide you along the four essential stages of your digital transformation.

Modeling
Analysis
Optimization
Real-Time

Build a digital twin of your automation system in weeks, not months

Model your process flow and robot interaction in the patented drag-and-drop environment of Digital Twin Studio® with intuitive auto-build features, a low-code interface, and a built-in library of 3D assets.

Emulate machine data and leave no stone unturned

Digital Twin Studio^® supports full data stack emulation to precisely align automation logic and behavior with your existing operational processes.

A patented neural network does the heavy lifting for full automation optimization

Let Digital Twin Studio® automatically attack areas for improvement, or easily define and compare custom scenarios to optimize fleet size, scheduling, maintenance, costing, and more.

Take things to the next level with real-time connectivity and machine learning

Turn your digital twin into a live control center. With real-time data integration, Digital Twin Studio® allows you to monitor and adjust your automation systems on the fly, ensuring you stay ahead of issues and maintain optimal performance.

Case Study: data-driven automation integration with Digital Twin Studio^®

Data-Driven Automation Integration with Digital Twin Studio

How ATI demonstrated feasibility of a proposed conveyance implementation

Digital Twin Studio^®: the Ultimate Automation Optimization Toolkit

Scalable Automation Systems
Modeling

Quickly build a detailed Digital Twin of your automation systems using our patented on-the-fly modeling technology. From robotic arms and conveyor systems to AGV pathways and sortation systems, capture every element of your automated facility with precision.

Advanced Automation Simulation &
Analysis

Leverage the robust simulation capabilities of Simcad DT® to detect bottlenecks, test various automation sequences, and refine equipment interactions. Run 'what-if' scenarios to optimize cycle times, minimize downtime, and enhance the overall efficiency of your automated processes.

Integrated Control System
Emulation

Emulate your entire automation stack by integrating PLC, SCADA, and MES data. Test and optimize equipment behaviors, conveyor speeds, buffer zones, and robotic pathways, ensuring seamless integration and optimal performance of all automation elements.

Real-Time Automation
Monitoring

Transform your Digital Twin into a live command center by connecting to your automation control systems with Digital Twin Studio®. Monitor real-time equipment status, track robotic interactions, and gain insights into material flow, allowing you to make data-driven adjustments on the fly.

AI-Powered Optimization for
Automation

Utilize AI and machine learning to identify inefficiencies in your automated processes. Our Digital Twin provides actionable insights, automatically adjusting equipment speeds, routing paths, and task prioritizations to maintain peak performance.

Predictive Forecasting & Automated Alerts

Stay ahead of operational challenges with dynamic forecasting, predictive analytics and real-time alerts. Identify potential automation breakdowns, path conflicts, or capacity overloads, and receive AI-driven solutions to resolve issues before they impact your productivity.

The DT Studio® Difference

Digital Twin Studio^® is your everyday data driven Automation management tool, whether you're
optimizing today’s picks, or planning for expansion weeks, months, or years down the road.

Slotting Optimization

Use Digital Twin Studio to connect the dots between inventory constraints, racking configuration, and cost factors that can impact efficiency.

Automation Integration

Want to add automation or optimize your current fleet? Test AGV, AMR, or ASRS logic in Digital Twin Studio before you invest to know you're making the right decision.

Pick Path Analysis

Digital Twin Studio shows your automation heat maps, spaghetti diagrams, and congestion analysis.

New Automation Design

Building a new automation? Expanding or adding more racking? Test your layouts in Digital Twin Studio to see how different designs impact efficiency.

Validate Control Logic Before Implementation

Ensure your automation systems work flawlessly from day one. Digital Twin Studio® lets you simulate and prove out control logic before rollout, catching issues early and saving time and resources. Peace of mind has never been this accessible.

Uncover Buffering Issues and Optimize Equipment Interaction

Buffer overflows and equipment clashes slowing you down? Digital Twin Studio® lets you identify potential buffering problems, adjust conveyor speeds, and fine-tune equipment interactions before they impact your operations.

Optimize AGV/STV Paths and Intersection Behavior

Navigating complex pathways is a breeze. Use Digital Twin Studio® to find the optimal paths for your AGVs and STVs, and manage intersection behaviors efficiently. Reduce congestion and improve material handling like never before.

Perfect Merge Logic, Slug Lengths, and Priorities

Merging multiple lines without a hitch is easy in Digital Twin Studio®. Simulate and refine merge logic, adjust slug lengths, and set priorities to achieve seamless integration of processes and keep your production lines moving smoothly.

Optimize PLC Logic

Testing PLC logic on the floor can be risky. With Digital Twin Studio®, you can determine expected PLC behavior in a virtual setting, ensuring your control systems perform exactly as intended when deployed. Safe testing leads to successful implementations.

Analyze Robot Performance and Interactions

Managing multiple robots can be complex. Digital Twin Studio® performs in-depth robot analysis and can simulate interactions between multiple robots. Optimize their performance and coordination to boost efficiency and reduce collisions.

Simplify Capacity Planning and Scheduling

Planning for demand changes shouldn’t be stressful. Use Digital Twin Studio® for capacity planning and scheduling, ensuring you meet production targets without overextending resources. Stay agile and prepared for whatever comes your way.

Optimize Equipment Sizing with Spatial Awareness

Ensure your equipment fits perfectly from the start. Digital Twin Studio® offers a spatially aware environment that accurately models your facility’s dimensions, helping you size and place equipment with confidence. Optimize layouts, prevent costly miscalculations, and make the most of your space.

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CONTACT US

3909 75th St. Ste 105,
Aurora, IL 60504
(630) 851-9474
(630) 566-0756

ABOUT US

With over 30 years of industry experience, we are proud to support over 3,600 clients worldwide, helping them achieve sustainable competitive advantages through advanced digital twin technology.

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