Emulation of a production cell including robot visionJune 2017, by Einevik, Johan and Kurri, John
'Using a virtual twin of a production cell, makes it possible for programming and different functional testing of panels to be performed in early stages of development. A virtual twin contributes to a simpler debugging and to identify problems and minimize cost in commissioning of the production cell. The aim for the project is to investigate how well an emulated cell will perform compared to the real production cell in a factory acceptance test. Another objective is to investigate how you can use real CAD models in the emulation and what type of criteria the models should meet. The project had a lot of challenges and one of them was the difficulty to emulate the safety systems. This was solved by bypassing the safety in the PLC program. One important thing about emulation is communication between the different software used in the system. In this project, it proved successful to distribute the software on three computers to ease the workload of the programs used in the emulation. To use the emulated model instead of the real system is still in the research phase but in this project a lot of useful applications could be identified that could change commissioning in the future.'
Virtual commissioning of a manufacturing system: Focus on verification of PLC logicJune 2017, by Putrus, Milad and Wisam, Milad
'Volvo Group Trucks Operations (GTO) in Skövde is a developing and successful company that works with continuous improvements and efficiency work tasks, to quickly enable the conditions for solve the problem. Volvo GTO and Projektengagemang want to rebuild the core making machine, where installation and programming of a new control system is included. To shorten the actual commissioning time in the project, Volvo has the ambition to be able to perform different test runs as well as to virtually verify the control system's program and function against an emulation model. The main purpose of the project is to build an emulation model in the emulation software Simumatik3D, where the virtual model is similar and reflects the real production equipment (Digital Twin). Using the model, virtual commissioning can be applied by verifying and validating the actual PLC logic against the emulation model, as well as detecting all errors prior to implementation in real life. The PLC logic is programmed in the programming software Tia Portal V14. The frame of reference has been implemented to study the theoretical background of emulation and virtual commissioning. The literature study analyzes several case studies previously done in the field. The model and PLC logic were validated against each other to investigate if the model is faithful. The communication between the different software has been obtained in order to control the various movements in the production system using the PLC logic. PLCSIM Advanced has been used where it represents a real PLC hardware to be able to execute the PLC logic in a virtual controller. An emulation model with 3D-CAD models is delivered and a virtual commissioning has been made using the model. The PLC logic has been validated and verified against the emulation model, where many different errors have been detected and corrected.'
Emulation of a manufacturing process: Focusing on maintenance and operator trainingJune 2017, by Tudero, Aitor and Azkue, Julen
'Having well-trained operators is a crucial need for Volvo Group Truck Operations (GTO). Mistakes from the factory staff may cause the production line to stop, and lead to economic losses. For this reason, Volvo GTO has decided to investigate the possibility of creating an emulation model from the production line and using it to train operators and maintenance personnel. The aim of this thesis is to develop an Operator Training Station (OTS) for the OP035 of the Volvo GTO Production Line 6. In the first part, a literature research was conducted, from which the authors gained insight into related fields such as emulation, virtual environments, and operator training. After that, an emulation model of theOP035 was created using some hardware from the factory. The real PLC program was analyzed and then modified in order to implement it to the emulation model. Then, communications were established between the different parts; emulation model and PLC program. Finally, a research of the common failures and problems of the production line was carried out, with the aim of being able to reproduce them in the Operator Training Station. Once the OTS was implemented, several tests had undergone to validate its behavior. These experiments verified that the emulation model was an accurate representation of the real system and validated its appropriateness for the operator training application.'
Virtual Commissioning: Emulation of a production cellJune 2016, by Binnberg, Dennis and Johansson, Viktor
'Volvo is continually updating and replacing their equipment and want to investigate the possibility to shorten the time it takes to implement changes and shorten the time in commissioning projects. The use of an emulation model of a production cell can shorten the commissioning time since the equipment and sequence of the cell can be thoroughly tested before implementation. Volvo also wants to investigate the possibility to validate equipment using emulation. The main objectives are to find an emulation software that suits Volvo’s needs and build an emulation model of an actual production cell at Volvo called G750. A literature review was performed in which the authors gained knowledge about virtual commissioning, simulation and emulation and the usage of these. A market survey was conducted in order to find emulation software that could handle Volvo’s complex production equipment consisting of ABB robots and Siemens PLC. A method for building emulation models of existing production equipment was found during the literature review. The software used to build the emulation model was Simumatik3D. Other software used to make the model as realistic as possible includes RobotStudio, WinCC and PLCSIM. The emulation model handles approximately 350 inputs and outputs. When the emulation model was finished experiments were conducted in order to answer research questions and to reach the main objectives. The experiments validate that the emulation model is representative of the real production cell regarding programming, fail scenarios and movement.'
Virtual commissioning : Verification of PLC logic in simulation programsJune 2015, by Johansson, Marcus and Nilsson, Jacob
Complete thesis (In Swedish)
To shorten project lead times Volvo Cars Skövde decided to explore the possibilities regarding verifi-cation of PLC-logic in simulation programs. The overall objective of the thesis was to analyze the pos-sibilities for establishing communication between the flow simulation program Plant Simulation and a PLC-device. A thorough understanding of the area virtual commissioning was obtained by writing the frame of reference and a literature review which served as basis for the continued practical work. Through a collection of interviews, discussions and an extensive literature review a better under-standing regarding how the communication between the different programs works, along with im-portant points that should be considered under a virtual commissioning project was obtained. A hy-pothetical system was developed in Plant Simulation by Volvo Cars Skövde to be used as a test sys-tem. The Simumatik3D model was created by emulating the Plant Simulation model and at the same time developing the PLC-logic in Siemens Step 7. During the development progress subsystems were verified in Simumatik3D against the created PLC-logic until the model was fully developed. To make sure that both the Simumatik3D model and the Plant Simulation model was valid a number of valida-tion points were tested. After the validation test the experimental phase started were different sce-narios were analyzed and tested to bring up any problems in the models to the surface. A thorough evaluation is presented in which the entire construction phase of the models is evaluated in terms of time required, advantages and disadvantages and communication with the PLC-device. The two pro-grams Simumatik3D and Plant Simulation was evaluated against one another in order to find out which program that is the most suited for virtual verification of PLC-logic. An overall methodology was developed based on the evaluation carried out and the experience gained from the implementa-tion of the work. The result from the developed methodology is presented which describes the parti-tion between the client and supplier, the communication between them and a visualization of the methodology-process. The result from the evaluation showed that Simumatik3D was more suitable for verification of PLC logic on a detailed level. The evaluation also showed that the PLC logic could be verified with Plant Simulation, but not on the same detailed level. Plant Simulation was more suit-able for making simulation models more realistic. Virtual commissioning of PLC-logic is a new con-cept on Volvo Cars Skövde and therefore can the result from this thesis form a basis for future work in this area. Virtual verification of PLC-logic is discussed in which several important aspects to think about is presented. The projects main goal to virtually verify PLC-logic in simulation programs was achieved and yielded good results, the partial objectives resulted in a thorough evaluation and future recommendations.'