The Role of a Behavioural Model for the Virtual Commissioning of Robotic Manufacturing Systems

Abstract This paper focuses on virtual commissioning of a robotic manufacturing system, its theoretical background, and an analysis of its importance in the design of automated and robotic systems. Virtual commissioning allows the PLC control program to be tested and debugged on a created digital model of the machine, called a digital twin of the machine. Just this solution can simulate and optimize the automated system design itself without the need to have real hardware (PLC, automation elements, or the whole machine/equipment). Virtual commissioning offers an effective alternative to reduce the risks and effort of real commissioning of the machine. This makes it possible to reduce the time to market and increase flexibility, efficiency, and quality. Virtual commissioning in a single-control system is a simple solution; we can either use the Software-in-the-Loop method with emulated PLC control, simulated behavioural model, and co-simulation model or Hardware-in-the-Loop method with real controller. The problem appears when we have various types of controller, including an industrial robot controller. The paper deals with the theoretical background and partial outlines of solutions in the use of different types of the control system, if interconnections or emulators for different control systems are available. The recommended solution is to use a separate solution for the 3D simulation of the robotic system and an independent solution for the behavioural model, which will be tested in the future.