VIRTUAL PROTOTYPING AND IMPLEMENTATION OF A PLC-BASED SORTING LINE USING DIGITAL TWIN SIMULATION IN FLEXSIM

Programmable logic controllers (PLC) are a main part of modern automated manufacturing systems. However, PLC programming presents a number of technical, organizational, and competency challenges. Therefore, the purpose of this article was to build a framework for virtual prototyping of PLC-based control systems in the FlexSim simulation environment, in accordance with Simulation Model-Based Systems Engineering (SMBSE). This work includes an example of conceptual design of a disassembly station and goes through the application of SIL (Software-in-the-Loop) and HIL (Hardware-in-the-Loop) methods and the Digital Twin of an automated sorting line. Expected results include the implementation of a prototype sorting line that will ensure sorting accuracy and efficiency. A working prototype of a sorting line based on an S7-1200 series PLC and a conveyor belt is also presented, together with conclusive remarks, including achieved sorting accuracy higher than 91.6%.