This thesis is dedicated to the development of the control software for a plywood panel composition plant and the modelling of its Digital Twin. These two separate projects are then brought together by the Virtual Commissioning procedure where the control software will be tested on the 3D model. The objective of the thesis is to demonstrate the effectiveness of a digital only approach for the commissioning phase with a practical demonstration on the development of a real plant. With the use of modern tools for 3D modelling and simulation we wanted to show the economical and time advantages in a digital approach, along with the improvement in quality of the resulting final product. The realization of the Digital Twin of the plant has been achieved through the use of the FlexSim software. The 3D model has then been connected, with the use of KEPServerEX, to the PLC code. In parallel, during the creation of the 3D model, the PLC code was developed with the use of SFC (Sequential Function Chart), LD (Ladder Diagram) and ST (Structured Text) languages. Together with it an HMI was created to visualize and control the plant during simulation. Thanks to this approach we had the possibility to test the code both during the development and as a final product. The simulation allowed us to find errors and weaknesses of the code without committing the significant economic resources usually required by the physical commissioning. Finally, we also implemented VR (Virtual Reality) in the project, allowing for even more testing capabilities. Thanks to the immersive experience, we had the possibility to visualize the plant in first person with much more freedom, and at the same time operate the HMI. The final results show how this approach allowed us to develop a complete and reliable control software for the plant, with low investments in time and money. These conclusions can be generalized demonstrating the effectiveness of Virtual Commissioning in the development of any production line.
Questa tesi è dedicata allo sviluppo del software di controllo per un impianto di composizione di pannelli in compensato e alla modellazione del suo Digital Twin. Questi due progetti distinti vengono poi accomunati dalla fase di Virtual Commissioning (VC) in cui il codice PLC verrà testato sul modello 3D. L'obiettivo della tesi è dimostrare l'efficacia di un approccio esclusivamente digitale per la fase di commissioning mediante una dimostrazione pratica sullo sviluppo di un impianto reale. Con l'uso di moderni strumenti di modellazione e simulazione 3D abbiamo voluto mostrare quali sono i vantaggi economici e di tempo nell'approccio digitale, insieme al miglioramento nella qualità del risultato finale. La realizzazione del Digital Twin dell'impianto è avvenuta tramite l'utilizzo del software FlexSim. Il modello 3D è stato quindi collegato con l'utilizzo di KEPServerEX al codice PLC. Parallelamente, durante la creazione del modello 3D, è stato sviluppato il codice PLC con l'utilizzo dei linguaggi SFC (Sequential Function Chart), LD (Ladder Diagram) e ST (Structured Text). Insieme ad esso è stata realizzata una HMI, per visualizzare e controllare l'impianto durante la simulazione. Grazie a questo approccio abbiamo avuto la possibilità di testare il codice sia in fase di sviluppo che come prodotto finale. La simulazione ci ha permesso di individuare errori e debolezze nel codice senza impegnare le notevoli risorse economiche normalmente richieste da un commissioning fisico. Infine, abbiamo implementato nel progetto tecnologie VR (Realtà Virtuale) permettendoci di avere un ulteriore strumento in fase di testing. Grazie all’esperienza immersiva, abbiamo avuto la possibilità di visualizzare l'impianto in prima persona con molta più libertà, e nel contempo azionare l'HMI gestito dal PLC. I risultati finali mostrano come questo approccio ci ha permesso di sviluppare un software di controllo completo e affidabile per l'impianto, con bassi investimenti in tempo e denaro. Queste conclusioni possono essere generalizzate per dimostrare l’efficacia del Virtual Commissioning nello sviluppo di un generico impianto di produzione.
Design and virtual commissioning of the control software for a plywood panel composition plant
MERLI, DANIELE;Paoletti, Lorenzo
2021/2022
Abstract
This thesis is dedicated to the development of the control software for a plywood panel composition plant and the modelling of its Digital Twin. These two separate projects are then brought together by the Virtual Commissioning procedure where the control software will be tested on the 3D model. The objective of the thesis is to demonstrate the effectiveness of a digital only approach for the commissioning phase with a practical demonstration on the development of a real plant. With the use of modern tools for 3D modelling and simulation we wanted to show the economical and time advantages in a digital approach, along with the improvement in quality of the resulting final product. The realization of the Digital Twin of the plant has been achieved through the use of the FlexSim software. The 3D model has then been connected, with the use of KEPServerEX, to the PLC code. In parallel, during the creation of the 3D model, the PLC code was developed with the use of SFC (Sequential Function Chart), LD (Ladder Diagram) and ST (Structured Text) languages. Together with it an HMI was created to visualize and control the plant during simulation. Thanks to this approach we had the possibility to test the code both during the development and as a final product. The simulation allowed us to find errors and weaknesses of the code without committing the significant economic resources usually required by the physical commissioning. Finally, we also implemented VR (Virtual Reality) in the project, allowing for even more testing capabilities. Thanks to the immersive experience, we had the possibility to visualize the plant in first person with much more freedom, and at the same time operate the HMI. The final results show how this approach allowed us to develop a complete and reliable control software for the plant, with low investments in time and money. These conclusions can be generalized demonstrating the effectiveness of Virtual Commissioning in the development of any production line.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/195719