This project is a complete virtual commissioning system connecting an ABB IRB 1200 robot in RobotStudio 2025.5 (RobotWare 6.16.03) with a Siemens S7-1214C PLC programmed in TIA Portal V17, all running simultaneously on a single Windows workstation without any physical hardware.
The robot is programmed in RAPID language with a state machine that waits for a digital input signal (diStart1) from the PLC, executes a pick-and-place sequence across four taught positions (pHome, pPickMachine1, pPickMachine2, pPlace), and returns three status signals (doRobotBusy, doAtHome, doJobDone) back to the PLC. The PLC ladder logic implements safety interlocks ensuring the robot only starts when confirmed at home and not busy.
Communication is bridged using NetToPLCSIM (port 102) which exposes the virtual PLCSim on a loopback network (127.0.0.1), and a RSConnectDIOToSnap7 SmartComponent inside RobotStudio reads and writes PLC memory bits in real time. A WinCC KTP700 Basic HMI provides a physical-style operator panel with a START button and three status indicator lamps mapped to 10 PLC tags across Q, I, and M address areas.
This workflow directly mirrors the virtual commissioning process used in real automotive and manufacturing plants — engineers validate robot programs and PLC interlocks fully in simulation before any physical hardware is installed on the factory floor, dramatically reducing commissioning time and risk.