The aim of this thesis is to create a custom application to simulate production lines. The first part explains the main reasons, benefits and current trends in the field of virtual commissioning and describes several simulation tools and engineering tools from Siemens. The second part is devoted to a detailed description of features, capabilities and application interface of the PLCSIM Advanced simulation tool. The third part is devoted to design and realization of the custom simulation application, which can be used for create conveyor lines and validate user PLC program in cooperation with PLCSIM Advanced tool. This simulator was created using Unity3D game engine and C# programming language. In the last part of the thesis, a simple simulation task is created in the simulator and is tested using PLC program and visualization created in the TIA Portal engineering framework.

This paper describes the development of a proof-of-concept application, which can be used to train people in the field of programmable logic controller (PLC) and robot programming. This concept leads to a better understanding, what kind of infrastructure and software packages can be combined, to not only have a visual representation of an industrial like scenario, but also the possibility to use commonly established programming environments such as TIA Portal, to set up a PLC program. In addi-tion, it provides insights on how OPC UA can be used and is suitable for controlling a typical six-axis industrial robot with the help of a PLC.

Vattenkraften är en viktig del av den svenska elförsörjningen och tillgodoser cirka 45 % av det årliga elbehovet i landet. Vattenkraften utnyttjar höjdskillnaden mellan inflödet och utflödet för att driva turbiner och producera el. I Sverige finns omkring 200 dammar med en fallhöjd större än 15 m och för höga nivåer vid någon av dessa skulle leda till ett dammbrott med omfattande konsekvenser. Ett viktigt område som det investeras mycket i idag är dammsäkerhet vilket går ut på att undvika okontrollerade översvämningar av dammen. Kännedom av fallhöjd och flöde är nödvändiga inom vattenkraft för att kunna beräkna producerad effekt och även vid dimensionering av dammar, vattenvägar och generatorer. Mättningar på inflödet till ett vattendrag anses vara mycket komplicerat och tidskrävande däremot kan utflödet genom utskoven beräknas med matematiska samband. Utskov avser öppningar i dammen som används för att avbörda vatten. Det finns således olika typer av utskov och det som påverkar valen är aspekter som kostnad, väderförhållanden, avbördningsförmåga, etc. För att undvika en möjlig överströmning av en damm dimensioneras ofta utskoven med avseende på vilken mängd vatten de bör avbörda. Ett krav som ofta ställs är att det ska vara möjligt att avbörda en vattendrags högsta vattennivå (HHQ). Några av de mest förekommande varianter av kontrollerade utskov i Sverige är valsdammar, luckdammar och bottenutskov.   Nivån i vattenmagasinet mäts upp med hjälp av sensorer som är placerade på olika platser vid dammen och uppmätta höga nivåer leder till att olika larmfunktioner löser ut. Regleringen av vattennivån sker då genom att avbörda vatten på ett kontrollerat sätt genom utskoven.  Genom att simulera regleringsprocessen av vattennivån i en virtuell miljö kan olika scenarier som kan uppstå vid magasinhantering testas på ett ekonomiskt sätt och hitta lämpliga reglerstrategier. Simuleringar är också en av de verktyg lyft fram inom industri 4.0 vilket kan bidra till framtidens lösningar inom automatiseringsprojekt. I arbetet studeras de olika beståndsdelar i ett vattenkraftverk och en tilltänkt metod presenteras för skapning av en virtuell modell av nivåregleringsprocessen i Siemens SIMIT, styrning av modellen via en virtuell PLC-enhet och visualisering av processen på en HMI-skärm. / Hydropower is an important part of the Swedish electricity supply and meets about 45% of the annual electricity needs in the country. Hydropower uses the height difference between inflow and outflow to power turbines and produces electricity. In Sweden, there are about 200 dams with a drop height greater than 15 m, and too high levels at any of these dams would lead to a dam break with extensive consequences. An important area in which a lot is invested today is dam safety, which is about avoiding uncontrolled flooding of the dam. Knowledge of drop height and water flow is necessary for hydropower to calculate the power produced and when dimensioning dams, waterways, and generators. Saturations on the inflow to a watercourse are very complicated and time-consuming, however, the outflow through the spillway can be calculated with mathematical correlations. Spillways refer to openings in the dam that are used to carry away water volumes. Thus, there are different types of spillways, and what influences the choices are aspects such as cost, weather conditions, etc. To avoid possible flooding of a dam, the spillways are often dimensioned with respect to the amount of water they should carry away. A requirement that is often made is that it must be able to carry away the highest water level (HHQ) of a watercourse.  The level in the water reservoir is measured with the help of sensors that are in different places by the dam and measured high levels lead to different alarm functions being triggered. The regulation of the water level then takes place by carrying away water in a controlled manner through the spillway. By simulating the regulation process of the water level in a virtual environment, different scenarios that can arise during reservoir management can be tested in an economical way and find suitable control strategies. Simulations are also one of the tools highlighted in industry 4.0, which can contribute to future solutions in automation projects. In the work, the various components of a hydropower plant are studied, and an intended method is presented for creating a virtual model of the level control process in Siemens SIMIT, controlling the model via a virtual PLC unit and visualizing the process on an HMI screen.

This diploma thesis deals with virtual commissioning of production system which is located in the laboratories of the Institute of Production Machines, Systems and Robotics at the BUT. The issue of virtual commissioning is described in the theoretical part of the thesis, followed by a description of each device located in this production system. The design of the 3D model, the design of the PLC control program and also the virtual commissioning itself are described in the practical part of the thesis. There is the creation of the robot‘s program described at the end of the thesis. Several Siemens software tools were used for virtual commissioning realization (TECNOMATIX Process Simulate, TIA Portal and PLCSIM Advanced 2.0).

The goal of my master‘s thesis is to create a digital twin of a testbed Barman. The Barman is a school model of autonomous mixed drinks production line that demonstrates the principles of Industry 4.0. In the theoretical part of the thesis, the choice of a suitable tool for virtualization is discussed. The Tecnomatix Process Simulate and the Mechatronic Concept Designer module integrated in the NX platform is compared. The practical part of the work is divided into two phases. The first phase was about looking for a way to integrate the robotic SCARA manipulator. The second phase was focused on the virtualization of the cell Shaker in the latter of the tools mentioned before. This work is designed as a guide for creating and verifying the concept of a digital twin.

The diploma thesis deals with the virtual commissioning of robotic workplace designed to engrave board materials and their subsequent packaging. The summary of the knowledge that contributes to the development of the virtual commissioning as well as description of each component of the given robotic cell, are described in the theoretical part. In the practical part are described procedures such as assembling of the simulation model in Process Simulate software, creating the PLC program in integrated development environment TIA Portal or creating visualization for HMI panel. In the end, the actual commissioning of the workplace was performed, followed by additional modification and validation of the robotic program.

The methods used today for the commissioning and validation of industrial machines requires theconstruction of physical prototypes. Those prototypes help the engineers to e.g. validate if theprogram code meant to control a machine works as intended. In recent years the development ofnew techniques for the commissioning and validation of industrial machines has changed rapidlythanks to the development of new software. The method used in this thesis is called simulationin the loop. Another method that can be benecial to use is hardware in the loop. Using thosemethods for the commissioning of a machine is called virtual commissioning. The simulation inthe loop method is used to simulate both the machine and the control system that operate thatmachine. This is called a digital twin, a virtual copy of the physical hardware and its control systemthat can be used without the need for a real prototype to be available.The software used in this thesis comes all from the company Siemens and those are TIA Portal,Mechatronics Concept Designer, SIMIT and PLCSim Advanced. By using those programs it waspossible to build a digital twin with rigid body dynamics and its control system of the industrialmodel that was given by the company Renholmen AB. This model contained all the necessarycomponents needed for a virtual commissioning project to be done without the need to be at thefactory oor.The results showed that it was possible to achieve a real time simulation, allowing the possibilityto trim the controller parameters without the need of a physical prototype. Design errors were alsofound thanks to the results of the simulation.This new technique has shown to be a useful tool due to most of the work could be done on a digitalmodel of the machine. Simulations can reduce the time to market for industrial machines and alsohelp engineers to validate and optimize the product at an early stage. This tool that can be usedto validate industrial machines before they are created.

The subject of this diploma thesis is the simulation and digital commissioning of a robotic production system for welding elements such as studs on sheet metal parts. The basis of the work is search of information related to industrial robots, PLC control, tools used for welding, fixtures, manipulators, sensors, safety and protection elements commonly used in such production systems. The second part of the work deals with the given problem and it is a virtual commissioning of the given concept of a robotic production system. This means creating its simulation model in the Process Simulate environment, selecting robots, creating robotic trajectories, collision analysis, creating sensors, signals and optimization. Last part includes the connection of the simulation model with the software S-7PLCSIM Advanced and TIA Portal, the creation of control PLC logic in the form of a program, visualization and verification of their functionality using the above-mentioned connection with the simulation model.

This thesis deals with the Industry 4.0 focusing on virtual manufacturing and its inte- gration into education. The aim of the thesis is to summarize and describe the Industry 4.0, and create necessary materials designed for teaching the virtual manufacturing. There is also a discussion on the real use of the virtual manufacturing and possible economic return for firms. Moreover, software programs for the virtual manufacturing available on the market, their options and their real use are also involved in the thesis. It also includes an application design for virtual manufacturing including laboratory tu- torials and the use of this application in education. There are also suggestions for other exercises that could move the teaching of the virtual manufacturing in the Czech Republic further.

Over the last few decades, the complexity and variety of automation systems have increased dramatically. Commissioning has grown more and more critical for the entire industry. Conventional commissioning is time-consuming and expensive. It's always been a challenge in manufacturing to put new designs into production or implement new technologies, control codes, or tactics. In Virtual Commissioning (VC), control programs of the physical system's Digital Twin (DT) can be validated in Software-in-the-Loop (SIL) before the actual commissioning. The emergence of new VC tools and methods has become a tremendous advantage, bringing the values of shorter duration, flexibility, and lower risks to the commissioning process. In this thesis, advanced process control was developed using the software Matlab and Simulink in conjunction with the engineering tools S7-PLCSIM Advanced and STEP 7 TIA Portal to conduct VC. A VC approach with four key steps is taken to evaluate the possibility of validating advanced process control. The steps are modeling DT of a rolling mill, model-based control design, simulation model development in Simulink, communication between the simulation model and the PLC program using S-7 TIA Portal, and PLCSIM Advanced. Also, a simulated Human-Machine Interface was designed to operate and visualize the process. VC of the rolling mill process was verified and validated by Model-in-the-Loop (MIL) and SIL simulation. The simulation gives satisfactory results as both MIL and SIL show identical outputs of the process.