FIIn traditional machine and control system development, testing has always been tied to a physical prototype. Test engineers queue for the same machine, the project stalls while waiting for fixes, and every hour of testing costs money. At the same time, critical early-stage decisions are made long before anyone can see their actual impact—often only months later, when the machine is started for the first time.
Simulator-assisted testing changes this dynamic entirely. When the control system is moved into a virtual model, development is no longer dependent on physical hardware. Testing can begin immediately from the very first software version -long before the first cylinder, valve, or control module has been assembled.
What does the simulator actually do, and why is it so effective?
A modern simulator is not a visual demo environment. At its best, it is a technically accurate digital twin that models machine behavior on both logical and physical levels. The control logic behaves exactly as it would on a real machine, I/O signals respond realistically, and hydraulic and mechanical dynamics are calculated through deep physics modeling. When the software issues a command, the simulator computes how the valve opens, how flow changes, how pressure rises, and how the resulting movement takes place.
The development team can also explore how the system behaves in edge cases that are difficult—or impossible—to reproduce in a physical environment. Overloads, pressure spikes, sensor failures, CAN-bus interruptions, sudden user errors—everything can be executed safely and repeatedly without risk of damage or hazardous situations. The simulator exposes issues that might otherwise surface only in the field.
When testing moves into a virtual environment, the entire development process changes
The biggest advantage of a simulator is not a single test, but the acceleration of the entire development cycle. When the control system can be tested long before a physical prototype exists, defects are identified weeks or even months before the machine is built. This directly improves schedules and costs: manufacturing stays on track, delivery does not slip, and software quality improves significantly.
Test engineers are no longer waiting for the prototype—the simulator is waiting for them. Regressions can be run automatically every night, and each new software package can be validated without manual preparation. Test automation software drives the simulator like a real machine: it starts the engine, actuates cylinders, reads sensor data, and verifies that the control logic behaves correctly.
The result is a development process where software quality matures with every version—not only after the prototype arrives. And when the physical machine is finally powered on, the control system already behaves reliably; testing no longer starts from zero.
What does this mean in practice?
For companies, simulator-assisted testing primarily means predictability. There is no need to anxiously wait for a prototype, and each software update no longer causes long delays at the test bench. Developers can focus on features, testers can design broader scenarios, and project managers can lead without constant firefighting.
The simulator also makes it possible to test situations that cannot—or should not—be tested on a real machine. Failure scenarios, high-cycle stress tests, and boundary-condition operation can all be run safely and consistently. When every regression test produces identical results, quality becomes measurable and verifiable.
A simulator is not just a test tool - it is a full development platform
At its best, the simulator is used far beyond testing. System designers can try new operation sequences without risk. Software developers can test logic without needing hardware. UI teams can see real behavioral responses to user actions. Even customers can be shown features before the machine exists.
Why you should adopt simulator-assisted testing now? And why AtoZ is the right partner?
Machines and control systems grow more complex every year. Hydraulic systems, intelligent automation, sensor fusion, and software-driven control require testing that can no longer rely solely on physical prototypes. Simulator-assisted testing enables companies to improve quality, shorten development cycles, and significantly reduce prototype-phase risks and costs.
Although AtoZ as a company is only eight years old, our experts have supported Finnish and international industrial companies in simulators, control systems, and test automation for nearly 20 years. This experience shows in practice: we know how to build a simulator-based testing process step by step, choose the right technologies and simulator tools, and integrate test automation seamlessly into the customer’s development pipeline.
When simulator-based testing is started with AtoZ, the customer is never left alone with the technology. We help with planning, implementation, deployment, and continuous improvement.
Final outcome
The result is a testing environment that makes product development faster, safer, and more consistent in quality. In addition, simulator-based testing provides clear, measurable cost efficiency: defects are found earlier, physical test hours decrease, and total development costs are reduced. This is often the point where decision-makers truly take notice—the simulator is not only a technical improvement but a direct cost saving, and often surprisingly affordable.
A simulator is no longer a luxury. It is a requirement for modern product development. With AtoZ, adopting it becomes smooth, effective, and reliable.