The Master’s thesis deals with virtual commissioning of the CNC machine tool changer. First deals with current state of knowledge with a systematic analysis of virtual commissioning. The 3D model is created by physical properties, sensors, actuators and control signals. In the last part of this thesis, a PLC program and visualization is created. The programs needed to create a virtual commissioning are jsou NX 12.0 - Mechatronic concept designer, SIMIT Simulation Platform V10.0 a TwinCAT 3.

This diploma thesis deals with digital commissioning of a robotic production system for laser cutting. First part of this thesis sums up teoretical knowledge of virtual commissioning, fundamentals of laser and laser cutting and system analysis of such a workplace. In practical part of this thesis, the workplace was designed including the workpiece clamping. The design and the digital commissioning itself was mediated by the software RobotStudio. In the programming language RAPID a control program was made and tuned. The workoplace was then virtually commissioned. For easier handling a user interface on FlexPendant was made.

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.

Industry 4.0 has caused exceptional changes in the industrial world. A relevant breakthrough is the concept of Cyber-Physical Production System (CPPS) which involves a system of interconnected entities with the main objective of achieving flexibility, which is essential for the manufacturing industries to remain competitive due to the actual demand for customization. The project suggests the use of a robot cell distribution called robot island as a solution to address this problem. In the implementation, a virtual model and program will be presented with flexible mobile robots, AGVs and a PLC. All are designed following the three principles of the CPS using RobotStudio and CODESYS to simulate and evaluate the results. The research demonstrates how autonomous, modular, flexible and adaptable to changes in product or production process system is, for example with the integration of the concept of the resource pool and variations in the product characteristics. The resulting executable is made with standardised modules so it can be extrapolated to other manufacturing processes, opening a wide range of possibilities for this island of robots. / <p>Utbytesstudenter</p>

Virtual Commissioning (VC) enables simulation of the combined work of mechanical, electrical, robot andautomation engineers prior to commissioning of the real production equipment. Hence, testing of areaslike collisions, PLC and robot code can be performed in risk free virtual environments and thus, errorscan be detected and corrected early in the development phase of the production equipment. Effectively,both the time and the cost of commissioning will decrease significantly. In addition, advantages likeoperator training, increased knowledge about the equipment, a more mature and optimized system priorto installation is enabled. Nowadays, the commissioning phase of a production system accounts for 25%of the total project time and research has shown that VC can decrease the commissioning time with upto 75%.However, despite all advantages and existing solutions that enables VC, it is not a standard amongmanufacturing companies nor production equipment providers to use VC today. Therefore, we wantedto investigate why VC is not a standard today.There are many barriers and challenges that must be solved prior to successful implementation of VC. Aglobal survey concerning simulation concluded that eight fields of action must be addressed in order tofacilitate the use of simulation. These eight fields address barriers and challenges and they are assumedto apply for VC too. The fields are categorized into four technical and four non-technical fields of action.The technical concerns: model re-use, modeling efficiency, integration and usability. The non-technicalconcerns: work-flow, education, acceptance and collaboration.The purpose of this project is to investigate barriers that prevent VC from becoming widely used inthe industry. Thus, each field of action was researched to better understand why VC is not commonlyused. In addition, the objective of the project is to provide an investigation regarding the technical andnon-technical fields of actions and how each of the parties along the value chain relate to each field.Therefore, the following research question was formed. What barriers are preventing VC from gainingmomentum and becoming widely used by the industry?Through our interviews we did not find any company that currently use VC.We conclude that it generallyis the non-technical fields of action that contain barriers that prevent VC from becoming a standard inthe industry. Especially, it is the organizational related barriers that are the most severe. Nowadays,there exist technical solutions that enables VC and the technical fields of action mainly treat modelingefficiency improvements. However, interoperability is considered to be the most severe technical barriertowards VC and is therefore an important area to improve. Nonetheless, we conclude that the technicalbarriers are considered less severe compared to the non-technical in terms of enabling VC to becomingwidely used. / Virtuell Idriftsättning (VC) Virtual Commissioning är ett aktuellt tillvägagångssätt som underlättarinstallationen av nya maskiner för producerande företag och därmed hjälper att möta ett tuffare produktionsklimat.VC minskar risken, tiden och kostnaden för idriftsättningsprojekt, eftersom att manknyter ihop olika ingenjörsdiscipliner till en gemensam simuleringsplattform där deras arbete kan valideras.Dessa discipliner gäller primärt, mekanik, el-installation, automation och robotik. Vidare så kanfördelar som operatörsträning, ökad kunskap om utrustning och högre mognadsgrad av optimerade systemvalideras innan installationen av maskinen påbörjas. I dagsläget tar idriftsättningen 25% av dentotala projekttiden och forskning visar på att VC kan minska detta med upp till 75%.Trots att VC innebär många fördelar och att det finns programvaror som möjliggör VC är det idaginte ett etablerat tillvägagångssätt inom industrin. Därför ville vi i vårt examensarbete undersöka deunderliggande anledningarna till detta.Det finns många trösklar och utmaningar som måste lösas innan en lyckad implementering av VC. Medgrunden från en global enkät som undersökte vilka faktorer hindrar simulering från att bli ett standardverktyginom industrin utkristalliserades åtta olika områden, så kallade fields of action. Dessa antas ävengälla för VC och de åtta områdena kan delas upp i fyra tekniska-och fyra icke-tekniska områden. Detekniska områdena berör modellåteranvändning, modelleringseffektivitet, integration och användbarhet.De icke-tekniska områdena berör arbetsmetod, utbildning, acceptans och samarbete.Syftet med denna rapport är att undersöka trösklar som hindrar VC från att bli en standard inomindustrin. De åtta områdena används alltså för att undersöka varför VC inte används. Vidare vardet viktigt för oss att ta reda på hur de olika aktörerna i värdekedjan såg på varje enskilt område.Därför utformade vi följande forskningsfråga. Vilka trösklar begränsar VC från att bli en standard inomindustrin?Det var inget av våra intervjuade företag som använde sig av VC på en vardaglig basis, det var dock någrasom genomförde pilotprojekt. Generellt sätt finns det trösklar till både de tekniska och icke-tekniskaområdena, men flest trösklar är kopplade till de icke-teknisk områdena. Därför är de icke-tekniskaområdena intressanta att åtgärda primärt. Även om det är tekniskt genomförbart att implementeraVC finns det många tekniska trösklar som kan göra att arbetet med simuleringsmodeller underlättar.Vidare är det största tekniska hindret begränsad interoperabilitet mellan programvaror. Det är dock deicke-tekniska områdena som till störst del begränsar VC från att bli en standard inom industrin.

Automation systems are becoming more and more integrated in today’s society. The complexities of these systems are increasing and with this, the demand for high quality during the developmental phases. This poses a challenge for companies developing systems. One solution emerging form this issue is the use of simulations and virtual commissioning.  In the thesis, the process of quality control and the effective use of simulations in automation system development projects are studied. The focus lies on the software part of the systems. The study was conducted as an interview study of personnel at an automation systems development company. After conducting the interviews, the information was analyzed. This was combined with general theory regarding quality control and testing methods in software development. The test methods of the quality control process were then combined with what was required by a simulator in order to preform them.  The results of the thesis is a detailed picture of the quality control process. Systems are tested twice with the same testing hierarchy, first during development and then during commissioning. The difference is that during development, the final physical hardware and process system are not conceded to the software. This impacts the software system functionality and limiting its testability. Using simulations during development can reduce the disparity between the systems before and after deployment, improving quality. Considerations regarding the extent of simulation need to be made in order for the value of the simulators’ error removing potential to be higher than the cost of developing the simulator. / Automationssystem blir mer och mer integrerade i dagens samhälle. Systemens komplexitet ökar och med det karven på hög kvalitet under utvecklingen. Detta blir en utmaning för de företag som utvecklar systemen. En lösning som är på uppgång för detta är användningen av simulering och virtuell driftsättning.  I denna rapport studeras processen för kvalitetskontroll och effektiv användning av simulering i utvecklingsprojekt av automationssystem. Fokus ligger på mjukvarudelen av systemen. Studien är gjord som en intervjustudie av personal från ett automationsutvecklings företag. Efter intervjuerna analyserades materialet och kombinerades med generella teorier om kvalitetskontroll och testning i mjukvaruutveckling. Processens tester kombinerades sedan med vad som krävs av en simulator för att utföra dessa. Resultatet av detta arbete är för det första en detaljerad bild av kvalitetskontrolls processen. Detta visar att systemen tests två gånger med samma testhierarki, först under utvecklingen och sedan under driftsättningen. Skillnaden är att under utvecklingen saknas den riktiga hårdvaran och process systemet vilket påverkar mjukvarans funktionalitet och begränsar testbarheten. Genom att använda simulering under utvecklingen kan skillnaden mellan systemen före och efter distribution vilket ökar kvaliteten. Överväganden gällande vilken nivå av simulering som behövs för att värdet av simulerings potentiella förmåga att ta bort fel skall bli göre en kostande för att utveckla simuleringen.

This diploma thesis contains description of design of robotic cell, which automates process of glass neck ring welding. Robot arm is used as manipulator of part between entry conveyor, induction heating, automatic welding machine and outgoing palette. Construction process contains of making layout of the cell, design of needed workstations and minimalize risk of harm for human operator. The final construction design is simulated to verify robot reach and find manipulation time.

The Master’s thesis deals with design of digital twins of machine tools and application of designed procedure on a case study – digital twin of the machine tool MCV 754 Quick. In the first part are described current roles of digital twins in the field of machine tools and also hardware and software options for creating them. Software and hardware tools by Siemens (Mechatronics Concept Designer and SIMIT) are used for the case study. The complex procedure of creating the digital twin is designed in the second part, starting with preparation of a model, ending with the virtual commissioning of the machine tool MCV 754 Quick. The procedure is described in detail, including preparation of 3D model of the machine tool, assignment of physical properties and joints, preparation of PLC, connection all the elements of the whole system: Sinumerik – SIMIT – Mechatronics Concept Designer and controlling the twin via CNC automation system. Output of the thesis is the virtually commissioned machine tool, capable of being controlled by Sinumerik 840D sl. This is the first step in development of the full-fledged digital twin of machine tool, which can be used for testing the functionality and capability of this new technology in industry.

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.

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.