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Success Story

Sim­u­la­tion of an auto­mat­ic assem­bly line


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Sim­u­la­tion and control

The advan­tage of sim­u­la­tion soft­ware is the pos­si­bil­i­ty to test real appli­ca­tions in a soft­ware envi­ron­ment on your local PC. This helps to reduce the down­time of the plant and offers sev­er­al oppor­tu­ni­ties when debug­ging the PLC-soft­ware. At Qual­i­ty Automa­tion we pro­vide inno­v­a­tive soft­ware solu­tions, and there­fore we con­struct­ed a test-appli­ca­tion on which we can val­i­date and ver­i­fy our PLC-soft­ware. The used sim­u­la­tion-tool „vir­tu­os“ is pro­vid­ed by the com­pa­ny of ISG — Indus­trielle Steuerungssoft­ware GmbH — Stuttgart. With this tool one can cre­ate a sim­u­la­tion and a visu­al­iza­tion of the appli­ca­tion – the process can be viewed as a 3D-modell.

The assem­bly line

As appli­ca­tion we sim­u­lat­ed an auto­mat­ic assem­bly line. Process: Sev­er­al dif­fer­ent com­po­nents are placed on a work­piece car­ri­er. After that place­ment the car­ri­er is encap­su­lat­ed with a hous­ing. The com­po­nents and the car­ri­er are locat­ed in stor­ages and can be inte­grat­ed into the process by con­vey­or belts. The com­po­nent place­ment and the encap­su­la­tion are per­formed by SCARA-Robots. Dur­ing a process cycle the work­piece car­ri­ers are placed on trans­port car­ri­ers and after the encap­su­la­tion they are sep­a­rat­ed from each oth­er. That sep­a­ra­tion and the stor­age process are exe­cut­ed by addi­tion­al SCARA-Robots. The PLC-Sys­tem “Twin­CAT” of the Beck­hoff com­pa­ny was used to con­trol the simulation.

Hard­ware in the loop

Because of the real-time capa­bil­i­ty of vir­tu­os, it is pos­si­ble to cre­ate a real image of the man­u­fac­tur­ing process. The PLC-pro­grams can be test­ed on the sim­u­la­tion, fail­ures can be found an elim­i­nat­ed even before the real com­mis­sion­ing. In this project, we were able to suc­cess­ful­ly val­i­date and ver­i­fy our PLC-pro­grams on the simulation.

Contact Person
QA Mitarbeiter Jochen Okon
Jochen Okon, M. Eng
Specializations: Control Engineering
Customer profile

ISG Industrielle Steuerungstechnik GmbH Rosenbergstrasse 28 D‑70174 Stuttgart
ISG-virtuos is a PC software solution for the simulation of machines and plants, coupled to real control engineering. It is possible to develop, test and to start-up control solutions at any time within the development phase of a machine or plant. ISG-virtuos is suitable for many users such as control, drive machine and plant manufacturers as well as operators.

ISG Stuttgart