Utilization of Virtual Commissioning for Simulation-Based Energy Modeling and Dimensioning of DC-Based Production Systems

Barth M, Herkel P, Gutwald B, Krüger JH, Schrage T, Reichenstein T, Franke J (2026)

Publication Type: Conference contribution

Publication year: 2026

Publisher: IEEE

City/Town: New York City

Pages Range: 700-710

Conference Proceedings Title: 2025 Winter Simulation Conference (WSC)

Event location: Seattle

DOI: 10.1109/WSC68292.2025.11339100

Abstract

The transition toward DC-based industrial grids demands accurate yet efficient planning methods. This paper presents a simulation-driven approach that integrates existing virtual commissioning (VC) models to estimate power demand in early design stages. A minimal-parameter modeling technique is proposed to extract dynamic load profiles from 3D multibody simulations, which are then used for electrical component sizing and system optimization. The methodology is validated using a demonstrator setup consisting of a lift tower and a six-axis industrial robot, both tested under AC and DC operation. Simulation results show close agreement with real measurements, highlighting the method's ability to capture realistic load behavior with low modeling effort. The approach offers seamless integration into existing planning workflows and supports dimensioning of safe, efficient, and regulation-compliant DC production systems. This contributes to reducing component oversizing, improving energy efficiency, and accelerating the adoption of DC grid architectures in industrial environments.

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How to cite

APA:

Barth, M., Herkel, P., Gutwald, B., Krüger, J.H., Schrage, T., Reichenstein, T., & Franke, J. (2025). Utilization of Virtual Commissioning for Simulation-Based Energy Modeling and Dimensioning of DC-Based Production Systems. In 2025 Winter Simulation Conference (WSC) (pp. 700-710). Seattle, US: New York City: IEEE.

MLA:

Barth, Martin, et al. "Utilization of Virtual Commissioning for Simulation-Based Energy Modeling and Dimensioning of DC-Based Production Systems." Proceedings of the 2025 Winter Simulation Conference (WSC), Seattle New York City: IEEE, 2025. 700-710.

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