Industrial Process Simulation through Digital Twin Modeling and PLC Programming

This thesis aligns with the principles of Industry 4.0, aiming to explore the potential of Digital Twin technology in the simulation of industrial processes. It leverages personal expertise in PLC programming to automate operations within a virtual environment. The study begins with a comprehensive analysis of an industrial process, including the identification of sensors and actuators embedded in its machinery. Based on the data collected during the analysis phase, a Digital Twin model is developed to replicate the observed industrial process. The model is designed with a level of detail sufficient to accurately mirror the mechanical behavior and operational dynamics of the real machines, within the constraints of the simulation environment. This modeling process includes the design of custom components using CAD software, which are subsequently imported into the simulation platform. Once integrated, these components are assembled to form complete machine systems. Controllers are then programmed to animate the machines, ensuring that their virtual behavior aligns with the intended physical operations. This virtual representation is programmed using PLC languages, and a connection is established between the Digital Twin software and the PLC software via a SoftPLC, enabling real-time interaction and control. The simulation provides a visual demonstration of the process operation and the logic implemented in the PLC, showcasing how automation can be effectively modeled and tested in a virtual setting.