Designing and Upgrading the Assembly Process and Verifying the Performance of the Pick to Light System Program

The aim of the work is to change the current program in the programmable logic controller (PLC) to be as close as possible to the real-world Pick to Light system in the automotive industry for installing individual car components. The change consists in completing the navigation and tutorial mode while preserving the original function of the program, which is to measure the time of each step in assembly of the components and the reading of the pieces from the trays. A simple virtual laboratory model was created which enables to test the program even if the access to the PLC and HMI panel is not possible. The partial goal was to modify the visualization of the program in the operator touch panel Human – Machine Interface (HMI). Another partial goal was to implement a new PLC program. In order to better understand the created program, the flowcharts were created and described for the main parts of the program.