Harit Vyas Portfolio

Industrial Project

Digital Twin

Made a exhaustive digital twin of the Smart Manufacturing Lab with two way communication with over 150000+ tags on each of the stations.

Visual Components

Kepware

Python Scripting

Reverse Kinematics

3D Modeling

PLC

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Digital Twin Station 3030

This is one of the stations in the entire lab, the following station has two way communication between the twin and the actual machine.

System Architecture

Designed and implemented a comprehensive digital twin architecture connecting PLC hardware to a real-time simulation environment using OPC-based communication. Structured and mapped 150,000+ industrial tags and enabled synchronized two-way data flow between physical equipment and the Visual Components model and the machines in real time with less than 20ms of lag.

Automation Logic & Python Scripting

Developed Python-based event logic within Visual Components to replicate production sequencing including part arrival, pneumatic clamping, robot positioning, tool engagement, torque cycle execution, validation pathways, and reject or retry states including simulating a light-guide. Implemented fault-state simulation and interlock logic to enable offline validation of cycle behavior prior to physical testing. Structured the digital twin to support process visualization, failure analysis, and production sequence debugging in a controlled simulation environment.

Robotics & Kinematic Modeling

Modeled UR10e joint structures and Bosch Rexroth actuator kinematics inside Visual Components, aligning coordinate systems and joint axes with real PLC-driven data streams. Mapped joint positions and control signals to simulation components to achieve synchronized motion fidelity between the physical station and digital model. Integrated reverse kinematics and mechanical constraints to accurately replicate fastening tool positioning, vertical actuator motion, and process cycle behavior.

Robotics & Kinematic Modeling

Communication & PLC Integration

Configured EtherNet/IP-based communication across the CompactLogix PLC, UR controller, and ESTIC torque system within the digital twin architecture. Implemented signal mapping, derived tags, scaling logic, and validation states to mirror real-world OK/NG conditions, fixture clamping, actuator positioning, and safety interlocks. Established reliable OPC-based middleware connectivity using Kepware to stream live PLC data into the simulation layer while preserving logical consistency and timing behavior.