Hardware-in-the-loop Simulation of a Programmable Logic Controller, Industrial Robots and Conveyor Systems Using RoboGuide

This paper presents an evaluation method for accessing a RoboGuide virtual robot cell and establishing control over a PLC-integrated robot system, with the primary objective of enhancing industrial automation capabilities. The experimental setup encompasses the simulation of a virtual robot cell featuring four Fanucs robots and two part conveyor belts, all controlled through Allen-Bradley PLC-based systems and a Human Machine Interface (HMI). This technological framework enables the testing and validation of control code on simulated industrial systems, ultimately contributing to increased operational efficiency and productivity. The study not only outlines the essential components involved in various industrial sectors but also assesses their efficacy, offering valuable insights into practical applications. Emphasizing the critical role of quality control and assurance in the automation sector for ensuring product standards and safety, the paper describes a simulation created within RoboGuide. In this simulation, the robot and PLC establish full-duplex communication over an Ethernet TCP/IP protocol. A custom control panel is developed, connecting the HMI to the PLC, thereby enabling the execution of robot actions or teaching pendant programs within the simulation environment. The core objective of this research is to assess the functionality of an assembly line using hardware-in-the-loop (HIL) simulation prior to the implementation of Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) in a real-world industrial setting.