Virtual Commissioning Digital Twin
Virtual commissioning platform connecting Siemens PLCs (PLCSIM Advanced) with ABB robot simulations in Visual Components. Uses Profinet, OPC-UA, and EtherCAT protocols for realistic validation before physical deployment. Features time synchronization between PLC scan cycles and simulation physics. Reduces on-site commissioning by 60-70%.
⚡ Challenges
- •Real-time PLC-simulation synchronization
- •Industrial protocol emulation
- •Regression testing automation
✓ Outcomes
- ✓60-70% reduction in commissioning time
- ✓First-power-on success in 3 projects
- ✓Methodology adopted by 2 OEMs
📖 Full Details
This virtual commissioning platform enables complete validation of automated manufacturing systems before any physical hardware exists. By connecting Siemens PLC programs running in PLCSIM Advanced with robot simulations in Visual Components and Tecnomatix, the platform creates a comprehensive digital twin that behaves identically to the physical system.
The communication architecture uses industrial protocols—Profinet for PLC-to-robot connections, OPC-UA for supervisory data, and EtherCAT for high-speed I/O simulation. Custom gateway software translates between simulation APIs and these protocols, allowing standard PLC programs to run without modification.
The validation workflow begins with PLC sequence testing against simulated I/O, verifying state machine logic and timing requirements. Robot programs then execute in simulation while the PLC controls cycle progression, validating handshaking and interlock sequences. Finally, complex multi-robot cells test collision avoidance and resource scheduling.
Significant innovations include a time synchronization system that ensures PLC scan cycles align with simulation physics timesteps, and a regression testing framework that automatically re-validates systems after program changes. The platform includes recording capabilities for replaying commissioning sessions and debugging timing issues.
This methodology has been refined through multiple automotive OEM projects at Virtual Manufacturing AB and Anilata AB, demonstrating 60-70% reduction in on-site commissioning time compared to traditional approaches. Several commissioning sessions have achieved first-power-on success with zero modifications required.
