Digital Twin Commissioning with Emulate3D

Summary

In this educational video, Henry Gan, a mechatronic specialist, demonstrates how to connect a virtual machine model to a PLC using Rockwell Automation's Emulate 3D software. He guides viewers through the process of selecting the IO browser, adding a PLC, and mapping PLC tags to the machine model's joints and sensors. The video also covers the importance of unit conversion between meters and millimeters for accurate data flow. Viewers learn to troubleshoot PLC code and adjust logic to prevent issues like box pile-up, making this a valuable resource for automation enthusiasts.

Takeaways

• 👋 Introduction: Henry Gan, a mechatronic specialist, introduces a tutorial on connecting a virtual machine model to a PLC using Rockwell Automation's Emulate 3D.
• 📺 Subscribe: Encourages viewers to subscribe to the ESN TV YouTube channel for automation support needs.
• 💻 Software Requirement: Users should have Emulate 3D Ultimate with a machine model ready for testing.
• 🔍 IO Browser: Demonstrates using the IO Browser toolbar in Emulate 3D to select and configure machine joints for interaction with numerical tags.
• 🔗 Device Discovery: Guides on how to find and select a PLC to connect with, using the FactoryTalk Network Browser.
• 📊 PLC Selection: The video uses a PLC named 'Virtual Commissioning' managed by FactoryTalk Logic's Echo for the demonstration.
• 🔄 Tag Association: Shows how to link specific PLC tags to the machine model's axes and control elements like the Gantry carriage and Z beam.
• 📏 Units Conversion: Explains the need for unit conversion between millimeters (PLC) and meters (Emulate 3D) for position tags.
• 🔄 IO Connection: Describes starting the IO connection to allow data flow between the PLC and Emulate 3D for real-time interaction.
• 🛠️ Debugging: Highlights the ability to use the PLC code within the simulation to detect and fix issues, such as box pile-up on a conveyor belt.
• 👍 Engagement: Asks viewers to like the video and subscribe to the notification bell for updates on new content.

Q & A

What is the main topic of the video by Henry Gan?

The video is about demonstrating how to connect a virtual machine model to a PLC using Rockwell Automation's Emulate 3D.

Who is the intended audience for this video?

The video is intended for mechatronic specialists, engineers, or anyone involved in automation and PLC programming.

What is the purpose of subscribing to the ESN TV YouTube channel as mentioned in the video?

Subscribing to the ESN TV YouTube channel ensures that viewers receive updates on all their automation support needs through the channel's content.

What software is required to be opened before starting the connection process in the video?

You need to open Emulate 3D Ultimate with the machine model you want to test.

What is the role of the IO browser toolbar in the process described?

The IO browser toolbar in Emulate 3D is used to select and configure the model's joints that will interact with numerical tags and tie in with PLC tags.

How does Emulate 3D identify and connect to the PLC?

Emulate 3D uses the factory talk links network browser to find and connect to the PLC, in this case, a PLC called 'virtual commissioning'.

What are the two axes that are tied together in the video example?

The X-axis is tied with the Gantry carriage and the Z-axis with the Z beam.

What is the function of the gripper sensor and gripper close tag in the video?

The gripper sensor acts as a virtual proximity switch to inform the PLC that a box has been picked up. The gripper close tag is a command from the PLC to close the gripper when it is set to one, and to open it when it is zero, simulating a pneumatic device operation.

Why is a unit conversion necessary for the position tags in the video?

A unit conversion is necessary because Emulate 3D expects values in meters, while the PLC sends tags in millimeters.

What is the benefit of starting the IO connection between the PLC and Emulate 3D?

Starting the IO connection allows data to flow between the PLC and Emulate 3D, enabling real-time testing and detection of issues with the code, sensors, or logic.

What action should be taken if boxes start to pile up in the simulation as seen in the video?

If boxes start to pile up, it indicates a need to adjust the PLC code to stop the process until the conveyor belt is cleared.

Outlines

00:00

🔌 Connecting Virtual Machine Model to PLC

Henry Gan, a mechatronic specialist, introduces a tutorial on integrating a virtual machine model with a PLC using Rockwell Automation's Emulate 3D software. The video guides viewers to subscribe to the ESN TV YouTube channel for automation support. It begins with the setup in Emulate 3D, where a machine model with preconfigured joints is selected. The IO browser toolbar is used to connect the model to PLC tags, allowing interaction with numerical tags. The tutorial demonstrates adding a PLC, in this case, 'Virtual Commissioning' running on FactoryTalk Logic's Echo, and selecting tags for the X and Z axes to control the Gantry carriage and Z beam. It also covers the connection of Boolean tags for a gripper sensor and gripper close command, simulating pneumatic device operation. A unit conversion is necessary for position tags from millimeters to meters. Once the IO connection is established, the video shows the testing of the Gantry movement and PLC code execution, which helps in identifying code issues and the need for logic adjustments, such as stopping the process when boxes accumulate on the conveyor belt.

Keywords

💡Mechatronic Specialist

A mechatronic specialist is a professional who specializes in the integration of mechanical engineering, electronics, and computer control systems to design and develop advanced automation systems. In the video's context, Henry Gan, the mechatronic specialist, is guiding viewers on how to connect a virtual machine model to a PLC, which is a crucial aspect of automation in industrial settings.

💡PLC (Programmable Logic Controller)

A PLC is an industrial digital computer used to control manufacturing processes, machines, or equipment through programmable logic. It is central to the video's theme as it is the device that the virtual machine model is being connected to, allowing for the simulation and testing of automated processes.

💡Rockwell Automation

Rockwell Automation is a company that provides industrial automation and digital transformation products and services. In the script, the video is about using Rockwell Automation's Emulate 3D software to connect a virtual machine model to a PLC, demonstrating the company's role in facilitating advanced automation solutions.

💡Emulate 3D

Emulate 3D is a software application used for simulation and visualization of machine models in a 3D environment. It is integral to the video's demonstration, as it is the platform where the virtual machine model is tested and connected to the PLC for virtual commissioning.

💡IO Browser

The IO Browser is a tool within the Emulate 3D software that allows users to view and interact with input and output (IO) devices. In the video, the IO Browser is used to select and connect the PLC to the virtual machine model, showcasing its role in establishing communication between hardware and software.

💡Numerical Tags

Numerical tags are identifiers used in automation to represent and track numerical values, such as positions or sensor readings. In the script, the preconfigured joints of the machine model are tied to numerical tags, which are then connected to the PLC tags to facilitate the simulation.

💡Gantry Carriage

A gantry carriage is a component of a gantry system, which is a type of machine tool that moves along a gantry frame. In the video, the x-axis of the gantry carriage is connected to the PLC, allowing the virtual model to simulate its movement in response to PLC commands.

💡Z-Beam

The Z-beam refers to the vertical beam or column in a machine that allows for vertical movement. In the video, the z-axis of the Z-beam is connected to the PLC, enabling the simulation of vertical motion controlled by the PLC.

💡Boolean Tags

Boolean tags are used to represent binary states, typically true or false, in an automation system. In the script, there is a gripper sensor and a gripper close tag, both of which are Boolean in nature, used to control and monitor the operation of a gripper mechanism in the simulation.

💡Pneumatic Device

A pneumatic device is a mechanical device that uses compressed air to perform work. In the video, the gripper close tag simulates the operation of a pneumatic device, where the gripper closes when the tag is set to one and opens when it is zero.

💡Unit Conversion

Unit conversion is the process of changing the values from one unit of measurement to another. In the video, a conversion is necessary because the PLC sends position tags in millimeters, while Emulate 3D expects values in meters, thus requiring a conversion to ensure compatibility between the two systems.

💡Jogging

Jogging in the context of machine control refers to the manual, incremental movement of a machine part to a precise position. In the video, jogging is used to manually move the gantry carriage and Z-beam to test the IO connection and the simulation's responsiveness.

💡FactoryTalk

FactoryTalk is a suite of industrial software solutions from Rockwell Automation for managing and optimizing manufacturing operations. In the script, FactoryTalk Logic's Echo is mentioned as the software running the virtual commissioning PLC, indicating its role in the automation process.

💡Virtual Commissioning

Virtual commissioning is the process of testing and verifying automated systems in a simulated environment before physical implementation. The video demonstrates this process by connecting a virtual machine model to a PLC and running simulations to detect and resolve issues in the PLC code.

Highlights

Introduction to the video by Henry Gan, a mechatronic specialist, focusing on connecting a virtual machine model to a PLC using Rockwell Automation's Emulate 3D.

Call to action for viewers to subscribe to the ESN TV YouTube channel for automation support needs.

Instructions to open Emulate 3D Ultimate with a specific machine model for testing.

Explanation of selecting the IO Browser toolbar and preconfigured joints for interaction with numerical tags.

Guidance on adding and waiting for the browser to populate currently communicating devices.

Note on the visibility of devices in FactoryTalk Links Network Browser and Emulate 3D compatibility.

Demonstration of finding and selecting a PLC for connection, specifically a 'virtual commissioning' PLC.

Description of selecting PLC tags and associating them with the X-axis and Z-axis of the machine model.

Mention of using position tags and the need for conversion from millimeters to meters for Emulate 3D.

Introduction of two Boolean type tags for the gripper sensor and gripper close command.

Explanation of the gripper close tag simulating the operation of a pneumatic device.

Details on starting the IO connection to facilitate data flow between the PLC and Emulate 3D.

Demonstration of jogging the Gantry carriage and Z beam to test the PLC code.

Discussion on detecting code issues and the ability to add sensors or logic as needed.

Observation of boxes piling up as an indicator for code adjustment to manage the conveyor belt.

Encouragement for viewers to like the video and subscribe to notifications for new content.

Closing remarks thanking viewers for watching the video on connecting a virtual machine model to a PLC.

Transcripts

I'm Henry Gan The mechatronic Specialist

with electric supply and equipment in

this video I'm going to show you how to

connect a virtual machine model to a PLC

using Rockwell automations emulate 3D

but before we get going please be sure

to subscribe to the ESN tv YouTube

channel for all your automation support

[Music]

needs if you haven't already please be

be sure to open up your copy of emulate

3D ultimate with the machine model you

want to test with in emulate 3D select

the io browser toolbar you can see that

we already have a model with

preconfigured joints that are able to

interact with numerical tags this is

where we will tie in our PLC tags select

add and then wait for the browser to

populate all the currently communicating

devices note that if the factory talk

links Network browser can see the device

then so can emulate 3D find the PLC you

want to connect to and select it in this

case we're using a PLC called virtual

commissioning that is being run by

Factory talk logic's Echo then select

okay once the PLC is added you will be

able to select from all the tags that

exist on the PLC in this case we're

going to tie together the xaxis with the

Gantry carriage and the z-axis with the

Z beam we can use the actual position

tags for each there are also two Boolean

type tags that we will need to tie in

there's one for the gripper sensor and

one for the gripper close the gripper

close tag is a tag coming from the PLC

that will command the gripper to close

when it is one and open when it is zero

this simulates the operation of a

pneumatic device the gripper sensor is a

virtual proximity switch that will tell

the PLC that a box has been picked up

for the position tags emulate 3D is

expecting the values to be in terms of

meters the PLC is sending a tag in terms

of millimeters so we're going to have to

do a quick conversion in the expression

column to convert from millimeters back

to meters for emulate 3D now we can

start the io connection so that the data

will begin to flow between the PLC and

emulate 3D we can jog the Gantry right

and left and

down and up we can also run the PLC code

this allows us to detect problems with

the code and add sensors or logic where

necessary you can see that after a while

the boxes start to pile up this lets us

know that we need to adjust our code to

stop the process until the conveyor belt

is cleared if you liked this video video

please click the like button and the

notification Bell so you'll be notified

when we post new videos thanks for

[Music]

watching