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How to run the SICARProcess Simulate DemoQVWUDWRU
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This is a short click-by-click tutorial of how to start the Software-in-the-Loop SICAR demonstrator with
Process Simulate Commisioning, TIA Portal, SIMATIC PLCSIM Advanced and WinCC software.
This document is structured as follows:
1. Start the software environment: slides 3 to 16 explain how to start and prepare the software tools
2. Start and reset the demonstrator: slides 17 to 19 explain how to run the demonstrator once you have started the tools and
how to reset the demonstrator
3. Use cases: slides 20 to 29 show you additional use cases you can check in this demonstrator
4. Troubleshooting and tips: slides 30 to 35 (e.g., FAQ: my simulation does not start, HMI explanation, etc.)

The software environment that you get with this virtual machine offers a 30-day license for Process Simulate
Commissioning software and a 21-day license for all SIMATIC software.

All files for the demo are stored under: C:\Users\Public\Documents\SICAR Demonstrator

You will find a shortcut to this folder in the desktop.

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Page 2
Start the software
environment
 Start PLCSIM AdvDQFHG (virtual S7-15XX PLC controller) (I)

Task: Prepare PLCSIM Advanced as shown and activate the trial license period Steps:
1. Start PLCSIM Advanced 2.0 and open
the user interface by right clicking the
2 PLCSIM symbol in the symbol bar at
the bottom right of the screen.
2. Click on the expand arrow as shown
and start a new instance. Name it
1 3 SICAR.
3. Once you start the instance, a pop-up
regarding “No valid License Key” will
appear.
Select the “PLCSIM Advanced” entry
and click on Activate to start the trial
period of SIMATIC PLCSIM
Advanced. Confirm with OK the next
window.
From this moment on, you can enjoy
PLCSIM Advanced’s full functionalities
for 21 days!

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Page 4
Start PLCSIM AdvDQFHG (virtual S7-15XX PLC controller) (II)

Task: Check that the instance has started Steps:

1. The LED should be yellow. This
means that instance is up but there is
no TIA Portal project. That is the next
step.

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Page 5
 Start TIA Portal (automation framework)

Task: Start TIA Portal and browse & open the project Steps:
1. Open the TIA Portal via the desktop
1 4 shortcut
2. On the TIA Portal welcome screen,
click on “Open existing project”
3. Click on Browse to look for the SICAR
TIA Portal project.
4. Browse to the folder:
C:\Users\Public\Documents\SICAR
Demonstrator\SICAR-Demo-TIA-
Project
And select the SICAR-Demo-TIA-
Project.ap15 file. Click Open
2 5. Wait till it opens and then click on
Open the project view at the bottom
5

Page 6
 Download the project into SIMATIC PLCSIM AdvDQFHG

Task: Follow the screenshots to load the project into PLCSIM Advanced Steps:
The PLCSIM Advanced instance SICAR is
1 3 already prepared for you
1. Select the Name.PLC15xx PLC and
load it into your PLCSIM Advanced
instance.
2. You may need to find your PLCSIM
instance first. Hit search and wait few
seconds
3. Select the PLC found with IP
192.168.0.1 and hit the Load button.
Confirm a pop-up regarding default
PG/PC interface if needed.
2 4. A new download window will pop up.
4 Select load.
5. Under Start modules, select the
Action Start module. Hit finish.
5

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Check that PLCSIM AdvDQFHG is now running

Task: Check that the PLC is now with green LED (in run mode after download) Steps:
1. Go to PLCSIM Advanced
If you close PLCSIM Advanced Control
1 2
panel by mistake, you can reopen it
by right clicking on the PLCSIM Advanced
icon on the icon bar on the bottom
right of Windows
2. Check how now the instance we
created is green! The PLC is up and
running.

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Page 8
Start the HMI runtime (virtual Human-Machine-Interface)

Task: Start the simulation for the HMI (WinCC runtime) Steps:
1. Go back to TIA Portal
2. Select the HMI1 as shown and and hit
the “Start Simulation” button. Wait
some time till the runtime loads. It will
compile it before it starts the WinCC
runtime to load the virtual HMI.

The first time you compile the HMI it

may take an extended amount of
time! This is because the SICAR
standard is powerful and has many
background features that need to be
loaded as well.

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Page 9
HMI-Setup (I)

Task: Enter the HMI number Steps:

1. Once the HMI runtime opens, enter
the number 1 on the HMI Number
field and press Save & close

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HMI-Setup (II)

Task: Your HMI should look like what is shown here. Steps:
1. Verify that your HMI looks like what
is shown here.
If there are any license dialogs click
on ok or noted.

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Page 11
HMI-Setup (III)

Task: Select operation mode Steps:

▪ From now onward everything can be
done through the HMI (apart from
resetting Process Simulate)
1. First select Operation mode area 1

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Page 12
HMI-Setup (IV)

Task: Start the cell Steps:

1. Press ACK to acknowledge errors
2. Press START button till it stops
blinking and it stays green (around 3-
1 2 5 seconds)
For an overview of the HMI or to
switch the HMI language from English
to German and vice versa, go to the
end of this document.

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Page 13
Start Process Simulate (robotic cell simulation)

Task: Open the Process Simulate Project Steps:

1. Start Process Simulate from the
desktop shortcut
2 2. Hit on the icon with a lightening to
1 open the project.
3. Brose to the folder SICAR
demonstrator/SICAR-Demo-Process-
Simulate and select the psz file. Click
open
Process Simulate 4. Wait for the project to open.
Standalone –
eMServer compatible

3 4

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Establish the PLC connection between Process Simulate and
PLCSIM Advanced
Task: Prepare PLCSIM Advanced connection in Process Simulate as shown Steps:
1. In Process Simulate hit F6 and
1 2 navigate the PLC tab as shown. (or
go to File/Option on the top left)
Select the Simulation mode “PLC”
and click on connection settings.
2. Click on Add.
3. Select the PLCSIM Advanced connection
4. Parameterize the connection as
shown. (a PLCSIM Advanced V2.0
instance named PLC needs to be running!).
Very important: keep the name as
3 shown (PLC)
4

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Page 15
Start the simulation in Process Simulate

Task: Hit the Play button Steps:

1. Go to the sequence editor (if you
cannot find it, search for it with the
search function at the top right
1 2. Press play. The simulation is now
running. If you need a reset, press
pause, reset and press play again.

At this point it may freeze a few seconds

if you press play for the first time. This is
because the robot controller needs to be
loaded for the first time.

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Start and reset the
demo
Starting the robotic cell in auto mode

Task: Initialize the cell, start the Process Simulate simulation and acknowledge all errors Steps:
1. Before you start, initialize the
2 automation program by clicking Init
once
2. Make sure the simulation in Process
Simulate is running. Nothing will move
but the time will be counting up!
3 3. Go to you HMI and select ACK to
1 acknowledge any error.
4. Press Start Sim button to start the
automatic mode of the robotic cell!

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Page 18
How to restart the simulation

Task: If anything does not work, simply restart the simulation Steps:
1. In Process Simulate, press pause and
3 reset
2. Go to the HMI and press INIT
1 3. Go to Process Simulate and start the
simulation by pressing the play button
4. Go to the HMI and acknowledge the
errors by pressing ACK on the top
right

4
2

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Page 19
Use cases
Move some devices via Hand0DQXDO mode on the HMI (I)

Task: Restart the whole cell as in slide 18 and set the hand (manual) mode Steps:
1. Restart the simulation as explained
before. You will be able to see in the
1 simulation how you jog manually
devices on the HMI
2. Go to the HMI and click MANUAL.
Most of the HMI icons should turn
blue

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Page 21
Move some devices via Hand0DQXDO mode on the HMI (II)

Task: Move some cell components in hand (manual) mode via HMI Steps:
1. Navigate to Manual OP-1 on the
bottom of the main HMI screen
2. Press the blue highlighted buttons to
change the devices. Try to turn the
table to position FWD and then back
to REV and then the lift to DOWN and
UP. The dark blue signs indicate the
position of the devices.

The current location of the devices is

1 2 shown by the dark blue boxes.

1 2

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Page 22
Check online via the HMI the sequence of any robot (I)

Task: Check the sequence of robot 1 how it is working Steps:

When running in automatic mode (hit Init

and start sim on the HMI), check the
1 following:

1. Now lets look into the PLC code of

this cell directly through the HMI.
Activate the detailed view by hitting
Graph-OV.
2. Then check the sequence of robot 1
by clicking on the button. (We
recommend only checking robot 1 as
it is the most interesting one)

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Page 23
Check online via the HMI the sequence of any robot (II)

Task: Check how the actual code is executed and can be accessed through the HMI Steps:

1. This page shows the sequence of

robot 1. Use the “Hand tool” and the “
magnifying glass” on the right hand
side to zoom into the conditions of
any one stage.
2. You can always go back on the top
left.

1
2

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Page 24
Check the Robot Signals (I)

Task: Check how the robot interface can be accessed via the HMI directly. Steps:

Now check the robot interface, there is an

invisible button at location 1, 2 and 3. If
you click it you can access the robot
interface.

1 2

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Page 25
Check the Robot Signals (II)

Task: Check how the robot interface can be accessed via the HMI directly. Steps:
These are the boolean signals needed to
control the robots.
On this screenshot the “startProgram”
and “FX_clpOpen” is true.

StartProgram should always be on.

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Page 26
Adjusting the cycles for tip dressing of robots (I)

Task: Change the cycles until the next tip dress (tool cleaning) Steps:
As you may have noticed, the two weld
robots perform tool cleaning from time to
time. This is called tip dressing where the
tips of the weld guns are grinded to clean
it from welding residues. You can change
the number of cycles after which the tip
dress is performed life during the demo.
For this you need to navigate the window
as shown.

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Page 27
Adjusting the cycles for tip dressing of robots (II)

Task: Change the cycles until the next tip dress (tool cleaning) Steps:
Navigate the limit values. On this window
many other maintenance counters or
cycle counter can be implemented, we
are interested into Limit Values.

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Page 28
Adjusting the cycles for tip dressing of robots (III)

Task: Change the cycles until the next tip dress (tool cleaning) Steps:
▪ Now you should see the limit values
window. The dataset 1 defines the
numbers of cycles after which tip dress
is performed. The difference between
the Set (maximum) and Prewarn
(warning limit) is the number of cycles
after which tip dress is performed.
▪ Currently after every 6-2 = 4 weld
operations the tip dress is performed.
If you change the Set value to 3 (select
it, then put a 3 in, then hit Enter, now
the tip dress is performed every
cycle (3-2 = 1) – neat.

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Troubleshooting and
tips
No PLC connection between Process Simulate and PLCSIM
Advanced - Verify Connection Setup
Task: Prepare PLCSIM Advanced as shown Steps:
1. In Process Simulate hit F6 and
1 2 navigate the PLC tab as shown.
Select the Simulation mode “PLC”
and click on connection settings.
2. Click on Add.
3. Select the PLCSIM Advanced connection
4. Parameterize the connection as
shown. (a PLCSIM Advanced V2.0
instance named PLC needs to be running!)

3
4

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Page 31
Check the TIA Portal code programmed using
the Siemens SICAR standard for automotive industries
Task: Have a look at our SICAR programming standard Steps:
This code could be loaded into a factory.
Go to TIA and check the following
1 elements:
1. First you can check the Devices &
Networks overview, there is a PLC
and a HMI parameterized, peripheral
IOs and robots.
2. The HW Config shows a S120, and
G120 drive, 2 Kuka Robots and 1
2 3 ABB robot. Also a HMI and a
peripheral IO device
3. Then check the graph sequence of
the R001 robot (the handling robot)
You can monitor this by going online
in TIA Portal and running in parallel
the simulation

The HMI and function blocks are 95%

out of the box from templates. Only
the general sequences need to be
manually programmed.

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Page 32
 Switch HMI language (German - English)

Task: You can switch languages on the HMI Steps:

You can change between English or
German language to be displayed on the
1 HMI
1. On the main HMI, click on System
button on the bottom right
2. Click on the flag to change from
German to English and vice versa

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General explanation of the HMI interface (I)

Task: Get an overview of the HMI Steps:

This cell follows the SICAR standard and
1 2 3 4 5 uses templates for all its cell devices.

1. The ON/OFF button can be used to

start/stop the PLCSIM Advanced instance
(in reality you can start/stop the PLC)
2. The start button is used to start the
operation, we have a customary start
sim button here for our convenience
3. The manual start button can be used
for manual operation. This is not
implemented in our demo model and
has no function, but is part of the
SICAR standard.
4. The array of numbers is to select the
controlled PLC (we can control up to
12 PLCs with this HMI) we only use
PLC 1 here.
5. Acknowledge any alarm.
6 7 6. Production Data counter (defines after
how many cycles tip dressing is being
performed)
7. Manual operation mode

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Page 34
General explanation of the HMI interface (II)

Task: Get an overview of the HMI Steps:

1. This window opens the sequence of
robot 1 (the one you have shown in
TIA portal).
2. This window shows the state of the
lift. The blue buttons show that the lift
3 is currently in the UP position. Arrows
2 indicate the direction the lift is
currently traveling toward (not
1 shown in this screen shot).
3. FX001 (fixture 1) is the clamp
mounted onto the lift. The small blue
4 bar on the left indicates that the clamp
is in the “HOME” position (open), the
big turquoise bar indicates an item
6 being in the clamp.
4. Clamp 1 on the table (FX002).
7 5 5. Clamp 2 on the table (FX003).
6. State of the turn table (TT001).
7. The state of the conveyer (can only
be on or off, the SKIDS on the
8 conveyer are controlled by the PLC
without HMI interface
8. Returns to the previous screen.
Special, OP-View, IF-Signals, Diagn, Tec-
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Unit Legend and System is not being
Page 35
used.