Virtual commissioning of an automatic boxing machine for hardware-in-the-loop control logic validation

Today the increase in complexity within the development process of automatic machines and automated systems and delivery times of the control project and the various mechanical movements. This is done by creating a virtual replica of the entire machine or only by the critical parts of the same through a physical simulation software. The objective of this thesis project is the design using a virtual commissioning software useful for testing the control logic, creating a virtual 3D model of a machine and connecting a real PLC to it. Corazza S.p.a. world leader in the construction of machines for soup cubes, melted cheeses and butter, which for the project it has provided the CAD design of the machine and the instrumentation as PC and motion controller. The software on which the 3D model was virtualized was delivered by Siemens and its name is NX-MCD, which provided support in the first phase of the virtual modeling. The project was divided into two parts: The generation of the stand-alone virtual model from the 3D CAD design. Hardware-in-the-loop connection with Schneider PLC to move the virtual model and test the control logic. Below there is a brief introduction to the chapters of the thesis: The first chapter presents the meaning of virtual commissioning, considering the various technologies used and what is the goal of this type of activity. In the second chapter there is an explanation of the software used to perform the thesis activity, studying its potential and its functionality. In he last part of the chapter there is a brief introduction of the competitors on the market. The third chapter presents the automatic boxing machine on which the project of virtual commissioning is done, studying the task of the machine and the critic part. In the fourth chapter explain how the virtual machine was connected to the real PLC. In the fifth chapter we describe the pros and cons that were found during this project on virtual commissioning.