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The Production Simulator Module is a free module that provides a simulator device that you can use with the MES modules. The simulator tags generate values you can use to simulate PLC tags. These generated tags are controlled through a CSV file, which is copied into the appropriate folder shown below:

PlatformIgnition VersionCopy .csv file to this folder
Windows7.9.xC:\Program Files\Inductive Automation\Ignition\data\drivers
8.xC:\Program Files\Inductive Automation\Ignition\data\opcua\devices\<device_name>
Linux7.9.x/var/lib/ignition/data/drivers
8.x/var/lib/ignition/data/opcua/devices/<device_name>

If the drivers directory doesn't exist, one of the following may be the reason:

  • Production Simulator Module is not installed or running.
  • Ignition may have been installed on an alternate disk. Try "D:" or another drive letter.


Each CSV file placed in the folder creates a unique and separate simulator that you can work with. A corresponding tag folder will be created in the Simulator folder of the OPC Browser for each CSV file.


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How to create CSV files for Production Simulator

You can simulate any real-life scenario by creating the CSV files. The example file below has two sections: Cells and Events

Cells Section

This section is optional, where you specify the information about the cell. 

Events Section

Events area is where you specify values for all the tags. You can add as many columns of tags you want to bring in. Make sure to put back slashes to organize in folders and specify the name of the tag you want as well as their datatypes.

Note

When you add an equipment to the production line, make sure to add a row in the table. For example, if the equipment is added in between the filler and capper, then the row added should be in between the row corresponding to filler and capper. See the table view of a CSV file shown below.

Create the Production Simulator Device

  1. On your Ignition Gateway webpage, select Configure, then in the left hand panel, under OPC-UA SERVER, select Devices, and click "Create new Device..."
  2. On the next page, select Production Simulator as your Type.
  3. You will then be prompted to give it a name and a description, then click "Create New Device."
  4. To verify that this process worked, go to Configure --> OPC Connections --> Quick Client. Expand Ignition OPC-UA Server, then Devices, then you should see the name you chose in step #3. Expand that, and you should see the structure of the simulator you previously placed in your "drivers" folder.
Table view of an example CSV file
<Cells>









NameUpstream CellDownstream CellStartup CountBackup StateInfeed Rate/HrRate Upper Variation (%)Rate Lower Variation (%)Outfeed Rate/HrUpper Waste (%)Lower Waste (%)
Filler
Sealer104360010084360000
SealerFillerCapper104360010084360000
CapperSealerLabeler104360010084360000
LabelerCapperInspection104360010084360000
InspectionLabelerCasepacker1043600100843600151
CasePackerInspectionPalletizer10436001008436000
PalletizerCasepacker
243601008436000











<Events>









DOWTimeFiller\StateSealer\StateCapper\StateLabeler\StateInspection\StateCasePacker\StatePalletizer\StateOperatorCardboard Vendor
Int32StringInt32Int32Int32Int32Int32Int32Int32StringString
112:00:00 AM



6

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112:00:15 AM



1

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112:00:30 AM22





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112:00:45 AM1





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112:01:00 AM






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112:01:15 AM


8


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112:01:30 AM


8


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112:01:45 AM


1


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112:02:00 AM

6



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112:02:15 AM

1



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112:02:30 AM





7Felicia SandovalNewport Materials
112:02:45 AM





7Felicia SandovalNewport Materials
112:03:00 AM





1Felicia SandovalNewport Materials
112:03:15 AM




3
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112:03:30 AM




1
Felicia SandovalNewport Materials
112:03:45 AM8





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112:04:00 AM8





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112:04:15 AM8





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Felicia SandovalNewport Materials
Relevant Definitions

Startup Count: The number of units of production at the beginning of the simulation. I.e. The machine has produced 10 units.

Backup State: Downtime state code for backup.

Infeed Rate/Hr: The Rate of units of production per unit time (hour) that the simulated infeed counter will accrue at. Suggest using the same unit (e.g. gallons, liters, individual parts, bottles, bushels, etc.) in this simulator. (Similar for Outfeed Rate/Hr.)

Rate Upper Variation: The percentage above the Infeed Rate/Hr the counter may go during the simulation.

Rate Lower Variation: The percentage below the Infeed Rate/Hr the counter may go during the simulation.

Upper and Lower Waste %: The boundaries of the simulated waste counter.

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