As part of my advanced industrial automation exploration, I developed a complete virtual simulation of a smart factory control process using Siemens TIA Portal, PLC Sim, HMI design, and ladder logic programming. The project emulates real-world industrial control logic and human-machine interaction in a factory environment, focusing on efficiency, safety, and modular design.
Abhishek Mahotra
May 29, 2025
Smart Factory Simulation Using TIA Portal:
To build a virtual model of an automated system that simulates real-time machine behavior using PLC and HMI integration. The focus was on:
Programming core machine operations using Ladder Logic.
Designing an intuitive HMI interface for operator control and visualization.
Testing and validating logic using PLC Sim without physical hardware.
Features Developed
Modular Ladder Logic Blocks
Timer-based control
Safety interlocks
Emergency stop logic
Start/Stop pushbutton simulation
Custom HMI Design
Real-time status indicators (Green/Red LEDs)
Touch-based controls (Start/Stop Buttons, Reset)
System Fault & Alarm notifications
Animation of process flows and status
Simulated Sensors & Actuators
Virtual limit switches
Indicator lamps
Motor start-stop logic
Feedback loops
Impact & Learning
This virtual factory simulation showcases my capability to design, program, and visualize automated control systems. It serves as a prototype for real-world industrial automation setups—demonstrating how digital twins and simulations can accelerate development cycles, reduce costs, and improve system reliability before physical deployment.
