This project implements a fully functioning production line simulation using Factory I/O and Siemens TIA Portal V17. The system automates the manufacturing of "Smart Bottle Caps," covering the entire lifecycle from raw material feeding to machining, assembly, and color-coded sorting.
The layout consists of a synchronized flow managed by a SIMATIC S7-1500 PLC. It integrates robotic pick-and-place units with CNC machining centers.
Figure 1: Overview of the Smart Cap Production Floor in Factory I/O
- Feeding: Random raw materials (Green/Blue) are placed onto the line.
- Machining: CNC stations fabricate Bases (3s) and Lids (6s).
- Assembly: Components are pressed together to form the final product.
- Sorting: Finished caps are sorted by color into designated storage ramps.
The HMI was developed in TIA Portal to provide real-time supervisory control and data acquisition (SCADA) for the operator.
| HMI Control Panel View | Functional Description & Control |
|---|---|
 |
Control Commands: - Start/Reset: Master control for the PLC sequence. - Stop Feeding: Halts new material while clearing the line. - Setpoint (V): Analog adjustment for conveyor speed. Live Statistics: - Counter: Total throughput of the plant. - Color Sort: Specific tracking for Green vs. Blue products. - Safety: Integrated Emergency Stop monitoring. |
To ensure industrial-grade reliability, the system includes:
- Sequence Monitoring: Detects if a part is stuck between stations.
- Hardware Interlocks: The HMI displays field-related alarms for any component failure.
- Emergency Protocols: Immediate halting of all actuators upon E-Stop activation.
The repository is organized to clearly separate the simulation environment from the automation logic:
TIA-FACTORY-IO/
├── PLC-HMI-Code/ # Siemens TIA Portal Project Folder
│ ├── ff.ap17 # Main TIA Portal Project File (V17)
│ ├── System/ # PLC System Configuration
│ └── [Internal Folders] # IM, Logs, XRef, AdditionalFiles
├── Production-Line-Scene # Factory I/O Scene File
├── HMI interface.png # HMI Screenshot for documentation
└── tia portail img.png # Factory I/O Screenshot for documentation