Manual VC With SIMIT and PLCSIM Advanced V100

SIMATIC Machine
Simulator - Virtual
Commissioning with
SIMIT and PLCSIM
Advanced
SIMATIC S7-1500T / PLCSIM Advaned V3.0 Upd2 /

Siemens
SIMIT V10.2 Upd2 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/109799724 Support
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Virtual Commissioning with SIMIT and PLCSIM Advanced

Entry-ID: 109799724, V1.0.0, 08/2021 2
Table of contents
Table of contents
Legal information ..................................................................................................... 2
1 Introduction .................................................................................................... 4
1.1 Overview ........................................................................................... 4
1.2 Machine description ........................................................................... 4
1.3 Components used ............................................................................. 5
2 Software setup................................................................................................ 7
2.1 TIA Portal .......................................................................................... 7
2.2 SIMIT ................................................................................................ 8
2.2.1 Structure of the SIMIT project ............................................................ 8
3 Operating the digital twin ............................................................................. 17
3.1 Starting the simulation ..................................................................... 17
3.2 Controlling the simulation ................................................................. 17
3.2.1 Production mode ............................................................................. 17
3.2.2 Manual mode................................................................................... 19
3.3 Error handling .................................................................................. 20
4 Appendix....................................................................................................... 22
4.1 Service and support ......................................................................... 22
4.2 Application support .......................................................................... 23
4.3 Links and literature .......................................................................... 23
© Siemens AG 2021 All rights reserved
4.4 Change documentation .................................................................... 24

Entry-ID: 109799724, V1.0.0, 08/2021 3
1 Introduction
1 Introduction
This application example demonstrates possibilities of virtual commissioning using
SIMATIC Machine Simulator including SIMIT and SIMATIC S7-PLCSIM Advanced.
For this purpose, a simple demo machine was designed. Goal of the machine is
filling and capping bottles travelling on a conveyor. PLC program for this machine
was prepared in TIA Portal and virtually commissioned with help of a digital twin
created in SIMIT.
1.1 Overview
This application example shows how to use SIMIT for the simulation of different
parts of your machine to successfully virtually commission your TIA project.
Therefore, following topics are implemented and will be explained in this document:
• Position and speed axis simulation
• PROFIsafe telegram 30 simulation
• External encoder simulation
• Digital input and output simulation
• Analog input and output simulation
• Safety signals simulation
• Visualization of simple movements
•
Simulation of products
• Basic simulation of processes
1.2 Machine description

The machine is designed to carry out the filling process and placing the cap on
bottles travelling on the conveyor. Layout of the machine is described in Figure 1-1.
The machine consists of three functional units. First is the conveyor together with
an external encoder to move bottles. Second is the fill station, which consists of
two axes to enable movement in axis X and Z, a fill nozzle, and a light barrier. Third
is the cap station, which also consists of two axes to enable movement in axis X
and Z, a cap holder, and a light barrier.
Figure 1-1 Machine layout
1 2 3 4
5 6 7
8 9

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1 Introduction
(1) Fill station axis Z

(2) Fill station axis X + fill nozzle
(3) Cap station axis Z
(4) Cap station axis X + cap holder
(5) Conveyor
(6) Bottle
(7) External encoder on conveyor
(8) Light barrier at fill station
(9) Light barrier at cap station
Machine is equipped with a control panel (Figure 1-2). The panel provides basic
control of the machine without need of a HMI. It is possible to adjust the liquid flow,
the liquid volume, or the line speed through potentiometers. By pressing the E-Stop
button, the safety program of the machine is triggered.
Figure 1-2 Control panel of the machine

1.3 Components used

This application example has been created with the following hardware and
software components:
Table 1-1
Component Article number
STEP 7 Professional V16 Upd3 6ES7822-1AA06-0YA5

SIMATIC S7-PLCSIM Advanced 3.0 Upd2 6ES7823-1FA02-0YA5
SIMIT S V10.2 Upd2 6DL8913-0AK20-0AB5
This application example consists of the following components:

Table 1-2
Component File name
Documentation Manual_VC_with_SIMIT_and_PLCSIM_Advanced_V100.pdf
SIMIT project SIMIT_DemoFillingStation_V100.simarc
STEP 7 project TIA_DemoFillingStation_V100.zap16

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1 Introduction
Limitations
The application example does not provide information on the following topics
• Basics of TIA Portal configuration
https://support.industry.siemens.com/cs/ww/en/view/109773506
• Basics of SIMIT
• Basics of Virtual Commissioning

• Description of SIMATIC Kinematics Control functionality

• Description of SIMATIC CPG Template functionality

In order to understand this application example, it is assumed that readers have

adequate knowledge of these topics.

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2 Software setup
2 Software setup
2.1 TIA Portal
The example application is based on a SIMATIC CPG Template1. Main operation,
the conveyor and the external encoder functionalities are covered in an equipment
module EM00. All functionalities regarding the fill station are placed in an
equipment module EM01 and for the cap station in an equipment module EM02.
Non-CPG folder contains logic to control a signal tower and button lights.
Figure 2-1 Program structure

The machine has two modes:

• Manual – jogging with axes, individual homing, moving the conveyor
• Production – automated homing, automated process of filling and capping
bottles
The library Kinematics Control2 was used to control the movement of fill and cap
stations during production mode. FB “FillStationProduction” contains all
functionalities regarding automated process of filling and FB
“CapStationProduction” contains all functionalities regarding automated process of
placing the cap on the bottle. The safety program handles inputs from the E-Stop
button or a safety door as well as axes through PROFIsafe telegrams. The
machine can be fully controlled with simplified HMI from SIMATIC CPG Template.
NOTE Password for the safety program is “siemens”.
1
For more info, please refer to: https://support.industry.siemens.com/cs/ww/en/view/109475572
2

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2 Software setup
2.2 SIMIT
The SIMIT simulation software in this application example was used to provide:
• Visualization of designed machine
• Simulation of drives
• Simulation of different types of IOs
• Simulation of control panel
• Simulation of material flow and filling process
2.2.1 Structure of the SIMIT project
Figure 2-2 SIMIT project structure

Visualization
“Visualization” chart contains a simplified model of the machine in a scale of 1 pix:
2 mm. This model is used to observe the movement of individual axes during the
simulation. The chart uses the SIMIT Control Library to simulate the signal tower or
the control panel3. The chart further contains the safety door mechanism and
interface to control generation of bottles. The bottle and axes movements are
displayed by animations in SIMIT4.
NOTE All actions regarding the control or observing of the digital twin behavior during
the simulation should be taken in this chart.
3
4

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2 Software setup
Figure 2-3 Chart “Visualization”

(1) Signal tower
(2) Model of machine
(3) Safety door mechanism
(4) Control panel
(5) Interface to control generation of bottles
3
2
4
Axis
• Station axes charts

Axes of fill and cap station use for communication standard SIEMENS
telegram 105, together with PROFIsafe telegram 30. For simulation of drives
with those settings, standard blocks were used5. Speed setpoint is integrated
to actual position, which is used for the simulated encoder and in
“Visualization” chart for individual axis. Actual position is derived back to actual
speed to provide feedback to the simulated drive.
Figure 2-4 Chart “CapStationAxisX”

(1) Actual position to actual speed calculation
(2) Speed setpoint to actual position calculation
5

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2 Software setup
• Chart “ConveyorAxis_ExtEncoder”
The conveyor axis is only speed controlled, therefore uses telegram 1, together
with PROFIsafe telegram 30. For communication with the external encoder,
which is placed on the belt, telegram 81 was used6. Signals from light barriers
are connected to the external encoder as measuring inputs.
Figure 2-5 Chart “ConveyorAxis_ExtEncoder”

(1) Signals from light barriers
(2) Speed setpoint used to simulate movement of bottles
1
6

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2 Software setup
IOs
• Chart “AI 4xU_I 2-wire ST_1”
Analog values of input signals coming from simulated potentiometers on the
control panel are transformed as a measurement of a physical value into the
raw value that can be used as analog input in the PLC.
Figure 2-6 Chart “AI 4xU_I 2-wire ST_1”
• Chart “AQ 2xU_I HF_1”

Analog values of output signals incoming from the PLC are recalculated to
physical values.
Figure 2-7 Chart “AQ 2xU_I HF_1”

• Chart “DI 8x24VDC ST_1”

Digital inputs to the PLC are simply interconnected with corresponding signals
from SIMIT
Figure 2-8 Chart “DI 8x24VDC ST_1”
• Chart “DQ 8x24VDC_0.5A ST_1”

Digital outputs from the PLC are simply interconnected with corresponding
signals in SIMIT
Figure 2-9 Chart “DQ 8x24VDC_0.5A ST_1”

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2 Software setup
• Chart “F-DI 8x24VDC HF_1”

Safety inputs to the PLC are interconnected through “FDI_8x” block, which was
taken from SIMIT Library for F-Components, with signals from SIMIT7.
Figure 2-10 Chart “F-DI 8x24VDC HF_1”
ProcessSimulation
Folder “ProcessSimulation” contains whole logic behind simulation of processes,

movements and actions in “Visualization” chart.
• Chart “CapAtStationVisibility”
Visibility of object “MainCap” which represents cap at station (1) in chart
“Visualization” is controlled by RS block (2) in chart “CapAtStationVisibility”.
Figure 2-11 Chart “CapAtStationVisibility”
7

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2 Software setup
• Chart “Constants”
All constants which are used in the SIMIT project are defined here.
Figure 2-12 Chart “Constants”
• Chart “ConvSpeedLinCalc”
This chart recalculates the conveyor speed from RPM to mm/s.
Figure 2-13 Chart “ConvSpeedLinCalc”

• Chart “FillBottleTimeCalc”
Time needed to fill the bottle based on the opening of the proportional valve is
calculated here.
Figure 2-14 Chart “FillBottleTimeCalc
• Chart “GenAtDistanceCalc”
Distance between bottles, so they are equally distributed on the belt, is
calculated here.
Figure 2-15 Chart “GenAtDistanceCalc”
• Chart “SimulateBottle1”
This chart contains whole logic regarding generation, movement, and filling of
the bottle 1.

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2 Software setup
If switch “Generate bottle(s)” from the control panel in chart “Visualization” is

pressed on, signal for generation of the bottle 1 (Figure 2-17, 1) is cyclically
switching on RS block “GenBottle1”. If switched on, objects “Bottle1” and “Fill1”
in the chart “Visualization” becomes visible and calculated linear speed of
conveyor is fetched to the input of integral block “ControlBottle1” (Figure 2-17,
2). This block outputs current position of the belt, through which objects
“Bottle1”, “Fill1” and “Cap1” are moved (Figure 2-18). If integrated position
reaches distance of light barriers, signals for measuring inputs are generated
(Figure 2-17, 3). As the bottle 1 passes through the fill station, output of ramp
block “ControlBottle1” (Figure 2-17, 4) controls scaling of object “Fill1” in the
chart “Visualization”, which represents filament of the bottle 1 (Figure 2-19). RS
block “ControlCap1” (Figure 2-17, 5) controls visibility of object “Cap1” (Figure
2-20).
Figure 2-16 Chart “SimulateBottle1”
2
4
5
Figure 2-17 Control of “Bottle1”

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2 Software setup
Figure 2-18 Control of “Fill1”
Figure 2-19 Control of “Cap1”

• Charts of bottles 2-5

Control logic of bottles from 2 to 5 is same. Only difference is the logic when
every additional bottle is generated. (Figure 2-20).
Figure 2-20 Generation of bottle 2 in chart “SimulateBottle2”
• Chart “LightBarrierSignals”
This chart collects signals incoming from particular “SimulateBottleX” charts
and sends final signal to the measuring input probe of the external encoder in
the chart “ConveyorAxis_ExtEncoder”.

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2 Software setup
Figure 2-21 Chart “LightBarrierSignals”
• Chart “SafetyDoor”
This chart checks if the safety door slider in the chart “Visualization” is in
closed position and sends signal to both channels of the safety input in the
chart “F-DI 8x24VDC HF_1”.
Figure 2-22 Chart “SafetyDoor”


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3 Operating the digital twin

3.1 Starting the simulation
The simulation will be started by clicking on the “Start/Play” button. An orange
background indicates that the simulation is active. The SIMATIC S7-PLCSIM
Advanced instance is automatically started in the background. To see the instance,
please additionally start SIMATIC S7-PLCSIM Advanced. After the simulation is
started, it is possible to download the TIA project. This is not inevitably necessary
since the memory card of the SIMATIC S7-PLCSIM Advanced instance will be
saved within the SIMIT project.
Figure 3-1 Starting the simulation in SIMIT
3.2 Controlling the simulation

The application example can be controlled either by the control panel from the
“Visualization” chart in the SIMIT or by the simulated HMI from the TIA portal.
3.2.1 Production mode
Table 3-1 shows procedure step-by-step how to successfully start the digital twin in
the production mode.
Table 3-1 Production mode
Screenshots Description
1. Open the “Visualization“ chart in SIMIT.
2. Drag “Safety door“ slider all the way to the

right to close the safety door and switch-
on the safety signal.

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3. Switch the machine from manual mode to
production mode by pressing “Production“
button (1). Acknowledge all errors by
pressing “Reset“ button (2). Start the
production mode by the pressing “Start“
button (3).
4. Homing to the end stop procedure of

stations starts. After it is done, stations
proceed to the ready positions and the
conveyor starts to move.
5. Choose amount of bottles (1), which will

be circulating on the conveyor, and press
“Generate bottle(s)“ switch (2). As long as
the switch is on, generation of bottles
continues cyclically.
6. The process of automated filling and
capping has started and the machine is
now fully operating.
7. It is possible now to:

• simulate response of the safety
program by pressing “E-Stop“
button (1)
• stop production mode by pressing
“Stop“ buton (2). The machine will
be in stopping state until all
bottles are gone from conveyor.
Therefore stop generating new
bottles to fully stop the machine.
• change the liquid flow by
adjusting the slider (3)
• change the liquid volume by
• change the line speed by

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3.2.2 Manual mode
Table 3-2 shows how to control the digital twin in the manual mode.
Table 3-3
1. Go to the TIA project, select the HMI (1)
and start simulation (2).
2. Open the “Visualization“ chart in SIMIT.
3. Drag “Safety door“ slider all the way to the

right to close the safety door and switch-
on the safety signal.
4. As visible on the HMI, the machine is in

manual mode and the aborted state after
start of the simulation. The machine can
be reset either by the control panel in
SIMIT or by pressing reset button on the
HMI (1). Start the manual mode by
pressing start button (2) and go to
“Manual Control“(3).
5. All axes should be now enabled with no

errors. It is needed to home axes first (1).
After that, it is possible to jog axes (2).
The conveyor can be moved as well (3).

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3.3 Error handling

During the simulation several error scenarios can occur. The machine goes to
aborted state, the signal tower shows red and the type of the error can be seen on
the HMI. To acknowledge, it is necessary to press “Reset” button on the control
panel or the HMI.
Station not back in time

If the line speed was set too high, it is possible that one of the stations might not
return to ready position in the time before arrival of new bottle (Figure 3-2). In such
case, the machine goes to aborted state and alarm “Station not back in time” can
be seen on the HMI.
Figure 3-2 Station not back in time

Mechanical end stop reached

If one of station axes reaches its mechanical end stop, it will result in following error
(Figure 3-3). In such case, machine goes to aborted state and alarm “Name of axis
Following error” can be seen on the HMI.
Figure 3-3 Axis X of fill station reached mechanical end stop
Emergency button pressed

In case of an emergency, “E-Stop” button on the control panel can be pressed to
trigger the safety program in the PLC (Figure 3-4). The machine goes to aborted
state and alarm “Emergency button pressed” can be seen on the HMI.

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Figure 3-4 E-Stop button pressed
Safety door opened

It is possible to open the safety door by sliding the slider to the left (Figure 3-5). In
such case, the safety program in the PLC is triggered, machine goes to aborted
state and alarm “Safety door are opened” can be seen on the HMI.
Figure 3-5 Safety door in the chart “Visualization”


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4 Appendix
4 Appendix
4.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
support.industry.siemens.com
Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts.
Please send queries to Technical Support via Web form:
support.industry.siemens.com/cs/my/src
SITRAIN – Digital Industry Academy

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
siemens.com/sitrain
Service offer
Our range of services includes the following:
• Plant data services
• Spare parts services
• Repair services
• On-site and maintenance services
• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
support.industry.siemens.com/cs/sc
Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for iOS and Android:
support.industry.siemens.com/cs/ww/en/sc/2067

Entry-ID: 109799724, V1.0.0, 08/2021 22
4 Appendix
4.2 Application support

Siemens AG
Digital Factory Division
Factory Automation
Production Machines
DF FA PMA APC
Frauenauracher Str. 80
91056 Erlangen, Germany
mailto: tech.team.motioncontrol@siemens.com
4.3 Links and literature

Table 4-1
No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example

\3\ Basics of TIA Portal configuration
\4\ Basics of SIMIT
\5\ Basics of Virtual Commissioning
\6\ Description of SIMATIC Kinematics Control functionality
\7\ Description of SIMATIC CPG Template functionality
\8\ DRIVES Behavior Library for SIMIT
\9\ SIMIT – Control Library
\10\ SIMIT components for the simulation of fail-safe modules of the S7-1500 /
ET200 MP / ET200 SP

Entry-ID: 109799724, V1.0.0, 08/2021 23
4 Appendix
4.4 Change documentation

Table 4-2
Version Date Modifications
V1.0 08/2021 First version

Entry-ID: 109799724, V1.0.0, 08/2021 24

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SIMATIC Machine

SIMATIC S7-1500T / PLCSIM Advaned V3.0 Upd2 /

Virtual Commissioning with SIMIT and PLCSIM Advanced

4.4 Change documentation .................................................................... 24

Virtual Commissioning with SIMIT and PLCSIM Advanced

1.2 Machine description

Figure 1-1 Machine layout

Virtual Commissioning with SIMIT and PLCSIM Advanced

(1) Fill station axis Z

Figure 1-2 Control panel of the machine

1.3 Components used

STEP 7 Professional V16 Upd3 6ES7822-1AA06-0YA5

This application example consists of the following components:

Virtual Commissioning with SIMIT and PLCSIM Advanced

• Basics of Virtual Commissioning

• Description of SIMATIC Kinematics Control functionality

• Description of SIMATIC CPG Template functionality

In order to understand this application example, it is assumed that readers have

adequate knowledge of these topics.

Virtual Commissioning with SIMIT and PLCSIM Advanced

Figure 2-1 Program structure

The machine has two modes:

NOTE Password for the safety program is “siemens”.

Virtual Commissioning with SIMIT and PLCSIM Advanced

2.2.1 Structure of the SIMIT project

Figure 2-2 SIMIT project structure

Virtual Commissioning with SIMIT and PLCSIM Advanced

Figure 2-3 Chart “Visualization”

• Station axes charts

Figure 2-4 Chart “CapStationAxisX”

Virtual Commissioning with SIMIT and PLCSIM Advanced

Figure 2-5 Chart “ConveyorAxis_ExtEncoder”

Virtual Commissioning with SIMIT and PLCSIM Advanced

Figure 2-6 Chart “AI 4xU_I 2-wire ST_1”

• Chart “AQ 2xU_I HF_1”

Figure 2-7 Chart “AQ 2xU_I HF_1”

• Chart “DI 8x24VDC ST_1”

Figure 2-8 Chart “DI 8x24VDC ST_1”

• Chart “DQ 8x24VDC_0.5A ST_1”

Figure 2-9 Chart “DQ 8x24VDC_0.5A ST_1”

Virtual Commissioning with SIMIT and PLCSIM Advanced

• Chart “F-DI 8x24VDC HF_1”

Figure 2-10 Chart “F-DI 8x24VDC HF_1”

Folder “ProcessSimulation” contains whole logic behind simulation of processes,

Figure 2-11 Chart “CapAtStationVisibility”

Virtual Commissioning with SIMIT and PLCSIM Advanced

Figure 2-12 Chart “Constants”

Figure 2-13 Chart “ConvSpeedLinCalc”

Figure 2-14 Chart “FillBottleTimeCalc

Figure 2-15 Chart “GenAtDistanceCalc”

Virtual Commissioning with SIMIT and PLCSIM Advanced

If switch “Generate bottle(s)” from the control panel in chart “Visualization” is

Figure 2-16 Chart “SimulateBottle1”

Figure 2-17 Control of “Bottle1”

Virtual Commissioning with SIMIT and PLCSIM Advanced

Figure 2-18 Control of “Fill1”

Figure 2-19 Control of “Cap1”

• Charts of bottles 2-5

Figure 2-20 Generation of bottle 2 in chart “SimulateBottle2”