Project Summary
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Abstract
Abstract
The aim of this project is to develop a digital twin of a Festo Modular Production System (MPS) station, integrating PLC programming, HMI design, and remote monitoring capabilities. The system will be modelled using Siemens NX, programmed in TIA Portal, and simulated using PLCSim Advanced to replicate real-world industrial automation scenarios. Additionally, Node-RED will be utilized to implement a remote monitoring dashboard, enabling real-time visualization of system performance.
By employing virtual commissioning and digital twin technology, this project aligns with Industry 4.0 principles, facilitating a cost-effective, flexible, and scalable approach to industrial automation testing and optimization.
Objectives:
Objectives:
The primary objective of this project is to simulate and monitor an automated production system without relying on physical hardware. This will be achieved through the following key tasks:
Develop a digital twin of the Festo MPS station using Siemens NX to replicate its mechanical and functional behaviours.
Program and simulate PLC control logic in the TIA Portal using PLCSim Advanced to execute automation tasks.
Design an HMI (Human-Machine Interface) within the TIA Portal for real-time system control and diagnostics.
Implement a Node-RED dashboard to monitor system performance and visualise key process parameters remotely.
Evaluate system behaviour through simulated testing, including fault injection and process optimisation.
Technologies & Tools:
Technologies & Tools:
The project integrates various industrial automation tools to create a realistic and functional simulation of the Festo MPS station:
Siemens NX – 3D modelling and digital twin development.
TIA Portal – PLC programming and HMI design.
PLCSim Advanced – Virtual PLC simulation without physical hardware.
Node-RED – Web-based remote monitoring dashboard.
Expected Deliverables:
Expected Deliverables:
By the end of this project, the following outputs will be developed:
A fully functional digital twin of the Festo MPS station modelled in Siemens NX.
A simulated PLC program in the TIA Portal, tested using PLCSim Advanced.
A user-friendly HMI for real-time system control and visualization.
A remote monitoring dashboard in Node-RED, providing live system data.
A comprehensive technical report documenting the design, implementation, and testing phases.
Relevance & Industry Impact:
Relevance & Industry Impact:
This project aligns with modern industrial automation trends, particularly in virtual commissioning, IIoT, and Industry 4.0. The use of a digital twin enables:
Cost-effective system testing without requiring physical equipment.
Improved reliability through early fault detection and system optimization.
Enhanced remote monitoring capabilities, reducing downtime and improving accessibility.
A scalable and flexible approach that can be extended to other industrial applications.
The outcomes of this project will demonstrate the benefits of digital twin technology in industrial automation, providing a practical, real-world example of how simulation and remote monitoring can enhance modern manufacturing processes.
Project Timeline
Project Timeline
Week 1-2: Research and gather requirements
Week 3-5: Develop the digital twin in Siemens NX
Week 6-8: Program PLC logic & design HMI in TIA Portal
Week 9-11: Integrate PLCSim Advanced & Node-RED
Week 12: Test, validate, and document findings
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