Software design and virtual commissioning of a robotic cell for an automotive packout application

Developing reliable control software for complex automated systems while ensuring its correctness before physical deployment remains a critical challenge in modern industrial automation. This thesis presents the design, implementation, and validation of the PLC control software of a robotic cell for an automotive packout application, developed at IMA Automation. The machine features multiple concurrent subsystems including a multi-axis gantry, an anthropomorphic robot, and a dynamic safety system, which must be controlled and coordinated to achieve the desired functionality while ensuring safety and reliability. The development followed a theory-to-practice approach, establishing a theoretical framework first, drawing on the IEC 61131-3 software engineering model, the GEMMA operating mode guide, the PLCopen motion control standard, and concurrent process synchronization theory. These principles were then systematically applied to the software development on a Siemens S7-1500 platform, through a three-layer hierarchical architecture complemented by a safety program compliant with IEC 61508. For validation, an existing simulation model was evolved into a Digital Twin, following a phased integration approach, enabling virtual commissioning. A structured campaign of nine test scenarios confirmed the correct functionality of all software domains and demonstrated the diagnostic and validation capability of the virtual environment, where the software was tested against a wide range of normal and fault conditions, without any risk to personnel or equipment. The results show that combining rigorous software engineering principles with virtual commissioning can significantly enhance the reliability of complex automated systems, while reducing time-to-market and development costs. The thesis contributes a practical case study and a methodological framework for future developments in the field of industrial automation software design.