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.