Virtual commissioning of automated manufacturing systems — Quality-handling station case study

Abstract

The aim of the contribution is to create an event-controlled simulation of an automated production system using selected simulation software according to analyses and creation PLC control program compatible with human-machine control interface (HMI) visualization. The programmer can test the control program without the need for additional hardware on a virtual model of the machine. This method is called as a Virtual Commissioning method. The question is whether these new digital technologies are beneficial in the development process of new machines. The theoretical part of the contribution deals with the evaluation of the current state of knowledge in the field of virtual commissioning systems from the perspective of the Industry 4.0 concept and the use of principles taken from the technology of digital twins for analysing the possibilities of productive support of simulation, programming and visualization of control. For the Virtual Commissioning of the Quality-handling station from a flexible production system. It was chosen Tecnomatix Process simulating software for the developing of the Digital Twin of the station that is suitable for the connection of the logical behaviour inputs and outputs of the Digital Twin to the PLCSIM emulator. The main goal is to create a functional PLC program, so that in the second phase the process of virtual commissioning can be tested by the Software-the-Loop method. The preparation of the simulation model consists in a sample of the control station model of the production system, the process of creating kinematic bonds, behaviour model, creating control signals in the Tecnomatix Process Simulate program. Programming procedure and acquaintance with control means in the Simatic Manager program, selection of communication interface and creation of control visualization. In the final work, validation is performed and evaluation supports the objectives and the results confirmed the benefits of the Virtual Commissioning tool.