PLC Inverse Kinematics Model-Driven Digital Twin Focused on HIL for a Flexible Robotic Cell

This paper focuses on the design, implementation and testing of a Digital Twin (DT) application for a assembly/disassembly (A/D) flexible robotic cell (FRC) assisted by ABB robotic manipulator (RM). A 3D virtual model is implemented in Siemens NX Mechatronics Concept Designer (MCD). S7-1200 PLC is programmed in Siemens TIA Portal, for both FRC and virtual model control, the last one based on inverse kinematics computation. A centralized architecture is applied for virtual FRC implementation and validation, to enable product simulation and for the automation control of the A/D manufacturing process. As part of the DT technology, Virtual Commissioning (VC) concept is used, to increase the production and performance, by optimizing tasks and to improve the traceability, by monitoring, analyzing and tracking every aspect of all manufacturing system. Moreover, VC significantly reduces potential human risks, delays and costs associated with the real on-site commissioning. To connect the FRC's PLC controllers with the NX MCD virtual plant model and for controlling the virtual model, Hardware-in-the-Loop (HIL) configuration and simulation strategy is adopted. Therefore Soft Commissioning approach is implemented and performed, by testing the designed PLC software and the behavior of the system using the real physical PLC. A SCADA application is also implemented, acting as a DT operator panel for process monitoring, data acquisition, analysis and visualization of the entire mechatronic system.