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realvirtual.io realvirtual v6.5.0

From CAD to Virtual Commissioning

This page shows the whole path to virtual commissioning in five steps. You start with CAD data and end with a PLC program that runs against the twin. Every step happens in the browser.

From CAD to virtual commissioning Five steps in a row: CAD import, kinematics, logic as Structured Text in the model, operator panel, and connect a real or simulated PLC. The last step can replace the Structured Text logic of step three with an external PLC that uses the same signals. 1 CAD import STEP, JT, GLB 2 Kinematics drives, axes 3 ST logic inside the model 4 Operator panel replaces the HMI 5 External PLC real or simulated Step 5 can take over from step 3: same signals, other source
Steps 3 and 5 are interchangeable sources of the same PLC signals.

1. Import the CAD model

Section titled “1. Import the CAD model”

Import the machine’s CAD data into the Editor. Local files are converted in the browser, and nothing is uploaded. The result is a tree of parts that does not move yet.

2. Add the kinematics

Section titled “2. Add the kinematics”

Define how the machine moves. Add drives to the parts that move along or around an axis. Closed-loop mechanisms such as linkages and scissor lifts use rigid-body mechanisms. Sensors and conveyors come from the material flow components. Test every movement in the Editor before you add logic.

3. Write the logic as Structured Text in the model

Section titled “3. Write the logic as Structured Text in the model”

The virtual PLC runs IEC 61131-3 Structured Text (ST) in the browser. Each program is stored in the model, on a PLC Program component. You need no external PLC and no build step.

The program reads and writes the twin’s PLC signals by name:

  • A PLC output is written by the PLC and read by the twin, such as a valve command or a motor output.
  • A PLC input is written by the twin and read by the PLC, such as a sensor or a button.

This is the same signal convention as with a real controller. For simple sequences without code, use logic steps instead.

4. Operate and test with the operator panel

Section titled “4. Operate and test with the operator panel”

The real machine panel does not exist yet during commissioning. The operator panel takes its place. It shows push buttons, selector switches, E-stops, lamps and a stack light, and it is wired to the PLC signals. Press Auto Start, trigger an E-stop and acknowledge the fault. Test the whole operating sequence with the ST logic from step 3, without the real HMI.

5. Connect a real or simulated PLC

Section titled “5. Connect a real or simulated PLC”

When the real control program is ready, connect it. realvirtual CONNECT links the twin to the controller. It supports, for example, Siemens S7 and PLCSIM Advanced, OPC UA, Modbus, TwinCAT ADS and MQTT. See Supported protocols for the full list.

The controller uses the same signal names as the ST program, so the twin, the operator panel and the lamps work without changes. When the controller writes its first output, the model changes from Simulation to PLC mode. Check the details in Connecting a PLC.

Take care with the ST programs from step 3:

  • A program that reads RV_SimulationMode stops writing when a real PLC takes over.
  • A program without this check keeps writing. Stop it in the PLC editor before you connect the controller.

If the connection ends, the model returns to its saved mode and the ST logic takes over again. See Simulation or PLC.

See also

Section titled “See also”