The manufacturing industry is quickly adapting to new technologies. Some of these trending technologies are virtual commissioning, virtual reality, and cloud-based technologies. This project summarizes these three technologies and aims to create a commissioning tool adapted to the 4.0 Industry. The project’s methodology was to analyse a problem and consequently create a solution that solves it. The process of designing and developing was repeated iteratively, each time an evaluation was made. The final product developed has shown that it is worth spending time introducing the cloudbased technologies inside many applications since it saves time and allows to work remotely. Applying virtual reality to virtual commissioning has proven to add efficiency. At the same time, it gives an immersive experience with a real-time display of quantitative data and the process itself in a visual mode without interfering with the actual production. With these two technologies, virtual commissioning evolves and goes a step further. This project also proved that the user experience and interface in this type of immersive applications need much attention on creating a comfortableinterface that does not fatigue or cause rejection in the user.

This thesis project aims to develop an instructing framework, concerning digital twin-based virtual commissioning, suitable for practical applications within the industrial sphere. The objectives set for the project are focused on constructing a framework which covers the initial specification, creation, development, and implementation of DTs within the circumstances of virtual commissioning. A literature review was performed to investigate the current state of the related academic fields. The gathered findings of the literary exploration were subsequently utilized to generate an initial framework. To test the instructing quality of the framework, a case study was conducted, involving the construction of a DT based on a real-world production process. Additional knowledge could be retrieved from the reflections of the case study, which prompted further alterations to the framework. The framework's final iteration covers the complete commissioning process, emphasising the virtual parts thatoccur at the beginning. In addition, the framework further shows how industrial organisations may store and repurpose DTs within their business practices. Suggested secondary applications of fully developed DTs were presented and discussed, including their impacting effects on supporting sustainable business practices.Therefore, it can be argued that the framework itself can be seen as a tool for supporting manufacturers to accentuate the presence of sustainability within their organisations.

Cette thèse présente le développement d'un simulateur de processus cryogéniques de grande taille appliqué aux installations cryogéniques de l'accélérateur de particules LHC (Large Hadron Collider) au CERN (Organisation Européenne pour la Recherche Nucléaire). Ce simulateur est basé sur une approche de modélisation orientée objet où chaque équipement (échangeur, turbine, compresseur, etc.) est représenté à partir d'un ensemble d'équations physiques algébro-différentielles. L'architecture de contrôle du CERN est également simulée en intégrant le contrôle réalisé par des automates programmables (PLC) avec le système de supervision. Ce simulateur à été développé pour servir différents desseins comme l'entraînement des opérateurs, la vérification des programmes automates (virtual commissioning) et l'optimisation des stratégies de contrôle. Le système cryogénique d'un détecteur de particules a d'abord été simulé pour valider les modèles, puis un liquéfacteur d'hélium a été modélisé pour réaliser un virtual commissioning. Les réfrigérateurs à hélium à 4,5 K du LHC ainsi que les unités de réfrigération à 1,8 K avec la ligne de distribution cryogénique du LHC ont également été modélisés et simulés. Le développement d'une nouvelle loi de commande basée sur un contrôle à modèle interne (IMC) en utilisant une commande robuste H infinie est présenté pour améliorer la régulation de la haute pression des réfrigérateurs à hélium du LHC. De plus, un système de pressions flottantes a été développé à partir du simulateur de manière à adapter automatiquement la puissance de réfrigération à la charge. Cette technique a pour principal objectif de réduire la puissance électrique des compresseurs.

Volvo Group Trucks Operations (GTO) i Skövde är ett utvecklande och framgångsrikt företag som arbetar med ständiga förbättringar och effektiviserar arbetsuppgifterna, för att snabbt kunna möjliggöra förutsättningarna för att hitta problemlösningar. Volvo GTO och Projektengagemang vill genomföra en ombyggnation av kärnskjutmaskinen, där installation och programmering av ett nytt styrsystem ingår. För att korta ner den verkliga driftsättningstiden i projektet, har Volvo ambitionen att kunna utföra olika testkörningar samt virtuellt verifiera styrsystemets program och funktion mot en emuleringsmodell. Huvudsyftet med examensarbetet är att bygga en emuleringsmodell i emuleringsmjukvaran Simumatik3D, där den virtuella modellen efterliknar och avspeglar den verkliga produktionsutrustningen (Digital tvilling). Med hjälp av modellen, kan en virtuell driftsättning tillämpas genom att verifiera och validera den verkliga PLC-logiken mot emuleringsmodellen samt upptäcka alla felaktigheter innan implementeringen i verkligheten. PLC-logiken programmeras i programmeringsmjukvaran Tia Portal V14. Den teroetiska referensramen har genomförts för att fördjupa sig i den teoretiska bakgrunden kring emulering och virtuell driftsättning. Litteraturstudien tar upp och analyserar olika fallstudier som tidigare gjorts inom området. Modellen och PLC-logiken validerades mot varandra för att undersöka hur verklighetstrogen modellen var. Kommunikationen mellan de olika mjukvarorna har erhållits för att med hjälp av PLC-logiken kunna styra de olika rörelserna i produktionssystemet. PLCSIM Advanced har använts där det föreställer en verklig PLC-hårdvara för att kunna exekvera PLC-logiken i en virtuell styrenhet.  Det som levereras är en emuleringsmodell med 3D-CAD modeller och en virtuell driftsättning har gjorts med hjälp av modellen. PLC-logiken har validerats och verifierats mot emuleringsmodellen, där många olika felaktigheter har upptäckts och korrigerats.

In this work I deal with the project of an automated robotic bartender, whose task is to show model concepts such as virtual commissioning, digital factory or industry 4.0. The work resolves two parts (cells) for the overall construction. Individual cells are solved from the design and realization of the construction through the virtual verification of operation to the design and realization of the control itself for the given cells. The construction solution was created in SolidEdge ST10. Virtual verification will be solved in the Tecnomatix Process Simulate program and the implementation of PLC and HMI control by Siemens is programmed in the TIA Portal. Wiring diagrams were drawn in the student version of the EPLAN design environment. Other colleagues work on other parts of the barman project.

Final thesis is focused on design of experimental workplace with industrial robots for manipulation operations, that will be used for educational and demonstrational purposes. Integration of sub-systems and workplace layout are worked out in this thesis. Key factor is so called virtual commissioning. Unique solution, which is contained within final thesis, combines several software tools for the design of robotic workplace. Static 3D model created in Autodesk Inventor Professional is imported into Tecnomatix Process Simulate, where dynamic 3D model is made – simulation model respectively. The control element is softPLC by Beckhoff company created in TwinCAT software. The connection of simulation model and control element is realized using standardized communication protocol OPC UA. This combination proved to be a cheap tool for virtual commissioning in practice, because only one personal computer is needed for the job.

The thesis deals with the automation of the production process of the workplace for forging of metal parts for a specific customer in a specific environment. In the introduction, there is an analysis of the industrial revolution. In the next part, the thesis is devoted to the virtual commissioning in Process Simulate. It then deals with the technical part of the design and detailed specifications of the individual components. Finally, the success of the project after the implementation is evaluated.

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.

This diploma thesis deals with the design and virtual commissioning of a robotic workplace designed for glueing and assembling a car headlight. The thesis contains a summary of available information on the matter of virtual commissioning and industrial robotics. It also contains a system analysis of the necessary equipment, followed by a design of several workplace variants. The final solution for which the 3D model is made is selected from them. With it, in the RobotStudio software, a simulation of all processes taking place at the workplace is created. On its base, a control program is created and debugged, and virtual commissioning of the workplace is performed.