Test PLC logic before building the machine: a transport-conveyor Digital Twin demo

Can you test a machine's PLC program before its conveyors, sensors and actuators physically exist? Yes — through virtual commissioning.

This demonstration was shared by Domenico Madeo and uses an educational Digital Twin example combining TIA Portal, S7-PLCSIM Advanced and Siemens NX Mechatronics Concept Designer (MCD). The original example was published in 2021: this article explains a useful engineering technique rather than presenting breaking news.

Watch the transport-conveyor Digital Twin demo

If the embedded player does not appear, watch the original video on YouTube. The video belongs to its original creator and is embedded here with attribution.

What's happening inside the demonstration?

NX MCD represents the mechanical model and dynamic behaviour of the 3D conveyor plant.
TIA Portal provides the PLC and HMI engineering environment.
PLCSIM Advanced simulates a PLC controller that exchanges signals with the virtual system.
Sensor changes in the model feed into the control logic, while PLC outputs drive virtual mechanisms.

The essential point is the closed-loop relationship: the simulated machine generates signals → the PLC processes them → simulated actuators move → the machine state changes. This goes beyond a visual 3D animation.

A practical engineering challenge

Imagine designing a sorting machine with three conveyors, photoelectric sensors, two diverters, an S7-1200 PLC and an HMI. Before fabrication, a virtual test environment could help answer:

What happens when products arrive too close together?
Does the logic detect a sensor stuck ON or a missing signal?
Can the sequence recover safely after Stop and Restart?
Are any conflicting actuator commands possible?

Virtual commissioning helps test control logic and sequencing, but does not replace physical verification of inertia, friction, mechanical tolerances or machine safety.

Relevance to machine builders

For machine builders, system integrators and PLC training teams, a digital twin can make it easier to evaluate designs jointly before assembly. Conveyor sorting, feeding, packaging and multi-actuator workstations are promising examples.

Original demonstration and learning resources:

The cover thumbnail is supplied by YouTube for the original video and was not AI-generated. Kỹ Sư Thập Cẩm independently prepared this commentary and does not claim ownership of the video.