Robotic Simulation Series Part II: Virtual Commissioning

By Deepak Prasad B H | August 9, 2024

Explore the benefits of virtual commissioning in manufacturing, where simulation integration with PLC programming accelerates production timelines and minimizes errors.

In this Q&A, Deepak Prasad B H discusses the concept and benefits of virtual commissioning as it relates to ongoing Industry 4.0 efforts to integrate robotics into manufacturing processes.

Q: What is virtual commissioning?

A: Virtual commissioning is a process that integrates the virtual signals from a simulation workcell, with the controls software signals (e.g. a programmable logic controller), for the purpose of testing, debugging and optimizing the behavior of various systems within the robotic workcell.

Q: What is a programmable logic controller (PLC) and how is it used in virtual commissioning?

A: Think of PLCs as industrial computers that contain customized programs or logics used to control the behavior of every connected device in a workcell. In other words, PLCs are like a brain making intelligent decisions based on the signals it receives from various sensors of the workcell.

A typical PLC setup contains the following components:

Power supply module
Processing module
Input module
Output module
Communication module
Cabinet (containing racks to mount the above modules)
Programming device
Programming software
Human machine interface (HMI)

Q: How does virtual commissioning differ from traditional commissioning?

A: Traditional commissioning usually begins after the various systems are manufactured, assembled and installed in the real world. A PLC programmer is then deployed to the factory to integrate the different components of the workcell. This is a tedious and labor-intensive process which often requires a lot of troubleshooting and significant downtime.

Virtual commissioning alleviates these issues by enabling the system integrator to develop PLC programs and virtually test different scenarios via the workcell’s “digital twin,” thereby eliminating the need to wait for the components to be built in real world. VC activity can commence alongside the detailed simulation phase, significantly reducing integration time, accelerating production timelines, and generating huge cost benefits for all stakeholders.

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Q: What are the various components of virtual commissioning?

A: Components will differ based on the various combinations of simulation and PLC platforms. However, for simplicity we will use the example of Siemens products.

The following components are required for a Siemens VC setup:

Process simulate

Create the “digital twin” of the robotic workcell.

VC license

Enable the integration with the Totally Integrated Automation (TIA) portal.

TIA Portal

Create PLC programs and HMI screens.

Physical PLC setup (containing all physical sensors and their connected devices)

Download and test the behavior of PLC programs.

PLC SIM advanced

Download and test the behavior of PLC programs (if a physical PLC-Sensor-Device combination are unavailable at the time of testing phase).

Q: Who are the beneficiaries of virtual commissioning?

A: The beneficiaries of virtual commissioning are:

Machine builders
Automotive OEMs
Automation solution providers
Engineering service companies

Q: What are the advantages of virtual commissioning?

A: Virtual commissioning provides the below advantages:

Early detection and correction of programming errors
Reduced time for system integration and subsequent Start of Production
Flexibility to test and implement optimized solutions without factory downtime
Early training of factory personnel

This is the second part of Actalent’s series on Robotic Simulation. The first article discussed the fundamentals of robotic simulation and how it works in manufacturing; it can be found here.