Home

Universal PLC Control & Digital Twin Simulation

Details
Hits: 12

In modern automation, the ability to work across different ecosystems is key. This showcase highlights my approach to Virtual Commissioning, where I develop complex control logic and verify it using high-fidelity 3D simulations. By connecting Factory I/O with both CODESYS and TIA Portal, I ensure that the code is hardware-agnostic and thoroughly debugged before deployment.

Technical Expertise

  • PLC Platforms: CODESYS V3.5 (IEC 61131-3) & Siemens TIA Portal (V17-V19).

  • Simulation Environment: Factory I/O (Ultimate Edition) for real-time 3D physics and I/O monitoring.

  • Protocols & Connectivity: Modbus TCP, OPC UA, and S7-PLCSIM.

  • Logic Style: Advanced SCL (Structured Text) for complex algorithms and Ladder Diagram (LAD) for sequential control.

Featured Case Study: Packaging & Sorting Line

I have designed a modular sorting system that processes items based on physical attributes.

  • Digital Twin Advantage: Using Factory I/O allowed for 100% virtual testing of the safety interlocks and sorting algorithms.

  • Efficiency: This workflow eliminates up to 90% of logical errors during the design phase, significantly reducing on-site commissioning costs.

 

Automated Sorting System – CODESYS & Factory I/O

Details
Hits: 3

This simulation showcases a modular sorting line developed using CODESYS V3.5.

Key Technical Highlights:

  • Control Logic: Written in Structured Text (ST) for high flexibility and readability.

  • Digital Twin: Real-time synchronization with Factory I/O via Modbus TCP.

  • Process: Automatic height detection and pneumatic sorting with overflow protection.

Hello, I'm Andre Stepniewski

I'm an Automation Engineer passionate about bridging the gap between virtual design and physical reality.

I specialize in developing PLC logic with a heavy focus on Virtual Commissioning. My goal is simple: to deliver code that is 100% tested and ready for action before it even reaches the factory floor. By using Factory I/O as a digital twin for CODESYS and TIA Portal, I save my clients time and protect their hardware from unexpected errors.

As a Junior Engineer, I bring a fresh, tech-forward perspective to every project. I don't just "write code" – I build simulated environments to ensure every sensor, motor, and safety interlock works perfectly.