AUTOMAÇÃO DE UMA CÉLULA LOGISTICA UTILIZANDO CLP S7-1200 E VALIDAÇÃO EM AMBIENTE VIRTUAL

Abstract

This work addresses the automation of a logistics cell (sorting, palletizing, and AS/RS), a topic of great relevance in the logistics 4.0 scenario. Validating the control logic for complex systems like this, when performed directly in the physical environment, entails high operational risk and elevated costs. Therefore, the Virtual Commissioning methodology is fundamental, as it allows for the mitigation of failures and the optimization of parameters in a secure environment. The objective of this study is to develop and validate this automation using a Hardware-in-the-Loop (HiL) architecture. To this end, a real Siemens S7-1200 Programmable Logic Controller (PLC) is integrated with a high-fidelity Digital Twin (Factory I/O) to test the control logic. Box sorting utilizes Analog Control with Deadband logic for dimensional precision. The palletizing sequencing ensures Traceability through synchronization via and indirect addressing, guaranteeing data organization. The storage subsystem (Automated Storage and Retrieval System — AS/RS) is controlled by a Finite State Machine (FSM), which guarantees operational determinism, and the precise positioning of the stacker crane is validated by a Deadband routine of 0.001 V on the analog axis. The results prove the effectiveness of the simulation in optimizing dynamic parameters and reducing risks in the final implementation of Logistics 4.0 systems.