| Most of the recent international manufacturing enterprises have recurred in the last decade to have fully automated and flexible plants to achieve their expected results. However, before the fully operational plant starts working, the process of commissioning represents a very complex step in many aspects, like how incorrect machinery handling, installation, and operation can directly generate a negative effect on the efficiency of the plant; since this equipment is composed of expensive, fragile devices, a wrong implementation of them can significantly delay the ongoing process. Virtual commissioning has been a favorable solution to these issues, saving a high amount of economic resources for both the commissioner and the enterprise.;This research covers the development of Virtual Commissioning with the Virtual Reality scenario along with physical interface by using communication protocol compatible with any class of PLCs.;This study will undertake using these following steps: Firstly, designed a PCB board communication protocol in a logical layer using Eagle 8.2.2 premium software. This will make it easier to work as a Data Acquisition to transfer data in the same communication layer. Secondly, making PLC connections by taking power supply 24VDC, PLC inputs/outputs to the microcontroller Digital Outputs and Digital Inputs respectively. The PLC controller uses RSLogix 500 software from Rockwell Automation to create a program and RSLinx Classic Lite to develop a communication with RS-232 in physical layer by selecting the controller model to obtain the program routine to create program and download program to the PLC to turn on Run mode. Thirdly, Virtual Reality automation plant consists of the Box packaging factory designed in Unity game engine. Also, using 3DS Max to clean all the meshes to easily export as FBX file to Unity will be built in the lab, and an attempt will be made to run and see the whole line of automation in virtual reality using Oculus Rift hardware and controllers with all the functionality. Fourthly, interfacing between PLC to the Virtual Reality environment by using Microcontroller Serial Communication Port. Upload and Run the programs in all the software's simultaneously in RSLogix 500 PLC programming and play in Unity 3D to observe the functionality of the system.;Finally, test and performance analysis of the developed system. It works according to the desired functionality. So, Implementation of Virtual Commissioning will be achieved. Implementation of Virtual Commissioning of the Box packaging factory line, benefits, economic justification will be demonstrated, and suggestions for designing a PCB board more efficiently in a way to organize all the components altogether without merging vias with the drills of the components to minimize the size of the board. |
