Digital twin in manufacturing by using programmable logic controller (PLC) Available to Purchase

Digital twin is one of the approaches to transform classical and traditional manufacturing to smart manufacturing and Industry Revolution 4.0, which received much attention in the manufacturing domain. Digital twin in manufacturing offers many advantages and solutions include close-loop feedback system, continuous real-time monitoring, or data acquisition through establishing a cyber-physical integration. The low cost and flexibility implementation of Programmable Logic Controller (PLC) enable the technology to become one of the most versatile tools and essential equipment for the automation industry today. However, PLC itself may not be suitable for real-time monitoring and control due to the characteristic of ladder diagram and normally it requires to work with extra devices to achieve the mentioned performance. The main objective of this paper is to develop a Graphic User Interface (GUI) as the cyber entity for real-monitoring and controlling towards the manufacturing process. The interaction between physical sensors, ladder diagram and GUI established cyber-physical integration system and provide engineers a real-time friendly approach to monitor and control the production. The ladder diagram and GUI control system are established by using CX-ONE (CX-Programmer and CX-Designer) together with OMRON PLC CP1L-E model training kits to prototyping the manufacturing cell. The result showed that the GUI allow operator to monitor as well as to control the real-time production.