TwinSea
Integrated digital twin, IoT, and HIL systems for real control hardware
Digital Twin, IoT, and HIL Testing Before the Field
TwinSea connects digital twins and Industrial IoT data acquisition with real PLC code, controllers, embedded software, sensor networks, I/O hardware, and test benches so teams can test behaviour and capture reliable operational data before equipment is commissioned offshore or on site.
Three Problems TwinSea Solves
Debugging PLC code on real machinery is slow, expensive, and dangerous. Virtual commissioning with TwinSea can reduce commissioning time by up to 75% because code arrives on site already tested.
Edge cases, failure modes, and emergency scenarios are difficult or unsafe to exercise on real hardware. TwinSea lets you stage any of these repeatably and deterministically.
Engineering, electrical, and software teams typically serialise around the physical machine. With TwinSea, software development starts against the digital twin from day one, in parallel with hardware build.
Virtual Commissioning Workflow
Step 1: Visualise
Import the CAD model and PLC logic into TwinSea. The visualisation layer provides real-time 3D feedback for engineers, operators, and stakeholders to see the same machine in the same state.
Step 2: Define
Set test objectives: what must the control code prove before it ships? Configure simulation parameters, environmental conditions, and events to inject. Define success/failure criteria upfront.
Step 3: Execute
Run scenarios with the real PLC in the loop. Multiple engineers can run the same scenario independently on the same digital twin to compare control strategies, tuning approaches, or algorithm variants.
Step 4: Analyse
Review recorded data with built-in analysis tools. Measure performance, reliability, and safety margins against success/failure criteria. Iterate on PLC code and retest until control software meets targets.
Supported Domains
Maritime and Offshore Projects
DP controllers, crane control on floating and jack-up platforms, cable lay tensioner control, dredging automation (TSHD and CSD), jacking system controllers, mooring and anchor handling, and ROV tooling.
Factory Automation
Conveyor systems, pick-and-place cells, assembly lines, packaging machines, robotic work cells, and material handling. Servo drives, VFDs, pneumatic actuators, and safety devices.
Construction Equipment
Excavators, cranes, piling machines, concrete handling equipment, and telescopic handlers. Hydraulic circuits with realistic pressure, flow, and temperature behaviour.
Autonomous Vessels
Navigation, perception, collision avoidance, thruster allocation, power management, and fault-tolerant control for autonomous and semi-autonomous maritime systems.
Robotics
Industrial arms, mobile robots, and hybrid systems. Kinematic and dynamic modelling, joint drives, and end-effector interactions for all control stack layers.
PLC and Controller Integration
TwinSea connects with real control hardware via a wide range of industrial communication protocols. Validated against Siemens (S7-300/400/1200/1500, TIA Portal), Beckhoff (TwinCAT 2 and 3), Bachmann (M1, M1COM), Rockwell (ControlLogix, CompactLogix, Studio 5000), and B&R Automation.
Supported protocols: OPC-UA, EtherCAT, PROFINET, Ethernet/IP, Modbus TCP/RTU, CAN, CANopen, J1939, and M1COM.
Validated PLC Platforms
- Siemens: S7-300, S7-400, S7-1200, S7-1500, TIA Portal
- Beckhoff: TwinCAT 2 and TwinCAT 3
- Bachmann: M1 controller family, M1COM protocol
- Rockwell Automation: ControlLogix, CompactLogix, Studio 5000
- B&R Automation
- Generic IEC 61131-3 controllers via OPC-UA or Modbus
Supported Protocols
Service Models
Complete Virtual Commissioning
MimeSeas builds the digital twin and IoT data layer, specifies and assembles the HIL hardware, integrates it with your PLC code or controllers, runs the test campaign, and delivers validated control software with full test evidence.
Platform Licensing
TwinSea is licensed to your engineering team with onboarding, training, and ongoing support. For clients who want virtual commissioning as an in-house capability.
HIL-as-a-Service
Hosted access to TwinSea environments from MimeSeas facilities, with MimeSeas engineering support. Suitable for periodic validation campaigns without capital investment.