Automotive Assembly Line
Virtual Commissioning & System Integration
This project demonstrates Malus Robotics’ capability to design, simulate, validate, and commission a complete automotive assembly line using advanced PLC programming, robotics integration, and digital twin–based virtual commissioning methodologies.
Project Summary
The automotive assembly line was engineered to support high-volume production with strict quality and safety requirements. Malus Robotics delivered a fully integrated automation system by combining robotics, PLC control, and digital twin validation. Virtual commissioning was employed extensively to test logic, sequencing, safety behavior, and robot coordination prior to physical deployment, significantly reducing commissioning risk and on-site downtime.
Industry
Automotive Manufacturing
System Type
Robotic Assembly Line
Execution Mode
Virtual Commissioning + On-Site Deployment
Project Objectives
- • Reduce on-site commissioning time and production ramp-up risk
- • Validate PLC logic and robot coordination before installation
- • Optimize robot paths, cycle times, and station balancing
- • Ensure safety compliance and fault-free system behavior
- • Deliver a scalable and future-ready automation architecture
Scope of Work
- • PLC programming and control logic development
- • Robot offline programming and teaching
- • Digital twin creation using 3D simulation
- • HMI and SCADA functional validation
- • Safety PLC integration and testing
- • Cycle time and throughput optimization
- • Virtual commissioning and simulation testing
- • On-site commissioning and production stabilization
System Architecture
- • PLC: Industrial PLC with integrated safety
- • Robots: Multi-axis industrial robots
- • Drives & Motion: Servo-controlled motion systems
- • Sensors & IO: Distributed IO and safety devices
- • Simulation Platform: WinMOD + 3D simulation tools
- • Digital Twin: PLC-coupled behavior model
- • Communication: TCP/IP, OPC UA
- • Validation: Collision, reach, and logic testing
Engineering Process
- 1. Requirement analysis and system definition
- 2. 3D layout development and digital twin creation
- 3. PLC and robot program integration
- 4. Functional, safety, and sequence testing
- 5. Virtual commissioning and optimization
- 6. On-site commissioning and production support
Results & Benefits
- • Significant reduction in on-site commissioning time
- • Early detection of logic and sequencing issues
- • Improved robot cycle times and throughput
- • Stable and reliable system behavior at start-up
- • Faster production ramp-up and reduced downtime