Virtual Commissioning is becoming more prominent in the industrial sector like aerospace, automation industries, power sector. Developing a 3D model and simulating any production process helps reduce the time and required resources. The VC process involves modelling, connectivity & testing, and validating the design and programs. Virtual commissioning concept and method is explained through a literature study. VC process has significant benefits like saving cost and time and limitations like the need for additional software and skilled engineers.

This thesis work presents an approach of creating a VC environment using Visual Components and TwinCAT for testing the PLC programs offline. A previously developed 3D model of the PTC production line using Robot Studio is presented. As an alternative, the 3D model of the PTC production line is created using Visual Components. The VC environment is formed using Robot Studio and Visual Components to a virtual PLC.

The VC environment formed is later compared for suggesting University West for further use. A sample 3D model is developed of an Imaginary production to test the PLC control. PLC programming is an essential requirement in the industrial sector for an automated process. The VC environment for the developed 3D model of imaginary production in Visual Components and TwinCAT is connected via ADS or OPC-UA server. Two of these interfaces OPC-UA and ADS are used for establishing the connection between Visual Components and a suitable, faster connection is explained.

After a successful connection between Visual Components and TwinCAT, the PLC program and robot program is developed. Later, the signals in the 3D model and PLC variables are mapped to test the PLC control in the simulation. This paper presents the simulation of a PLC controlled model of an imaginary production line to test the PLC programs offline.