[Plant Simulation Study #27] – Battery Pack Assembly Demo
Battery Pack Assembly Simulation Using Siemens Tecnomatix Plant Simulation
📘 Overview
This study demonstrates a Battery Pack Assembly process simulation built with
Siemens Tecnomatix Plant Simulation.
It visualizes a fully automated assembly line using industrial robots for assembly, screwing, and wiring tasks —
all within a 3D digital twin environment.
The simulation also analyzes equipment utilization, UPH (Units Per Hour), and UPD (Units Per Day) in real time,
showing how data-driven visualization can improve process understanding and manufacturing efficiency.
📺 Watch the Video
🎥 Plant Simulation Study (27) – Battery Pack Assembly Demo
👉 https://youtu.be/b5GoMZvBerc
💡 Key Simulation Concepts
1️⃣ Battery Pack Assembly Line
- Battery modules move along a conveyor system, stopping at each assembly station.
- Robots perform assembly, screwing, and wiring automatically at each stage.
- The 3D environment provides a realistic visualization of synchronized robot and conveyor operations.
2️⃣ Real-Time Performance Monitoring
- The simulation continuously tracks equipment utilization, production throughput (UPH),
and available components (UPD). - Worker Statistics and resource data are visualized to identify bottlenecks and optimize cycle times.
📊 These real-time metrics help engineers detect process inefficiencies and plan capacity improvements.
⚙️ Modeling Approach
⚠️ Common Mistake
Many modelers try to build everything with SimTalk scripts,
which significantly increases modeling time and reduces maintainability.
This often leads to delayed analysis and reduced simulation accuracy.
💡 Recommended Practice
- Utilize Plant Simulation’s built-in objects and functions instead of writing unnecessary code.
- Focus on connecting standard objects rather than building everything from scratch.
- Keep SimTalk usage minimal, only for essential custom logic.
“Efficient modeling starts with knowing how to use what’s already available.”
🎬 Simulation Result
In the final part of the demo, the simulation speed is increased to show the full production sequence.
Robots, conveyors, and modules work together seamlessly,
illustrating synchronized operations and efficient flow across the assembly line.
The result: a fast, stable, and highly visual battery pack assembly simulation
that accurately reflects real-world manufacturing behavior.
✨ Conclusion
This demo shows how to create a Digital Twin of a battery pack assembly process using Siemens Plant Simulation.
By combining built-in features with a modular design approach,
you can build realistic and maintainable simulation models without excessive coding.
✅ Key Takeaways
- Robot-based Battery Pack Assembly in 3D
- Real-time KPI tracking (UPH, utilization)
- Reduced modeling time by minimizing SimTalk scripts
📩 Contact & Collaboration
- Email: rnjsxodnr11@gmail.com
- LinkedIn: www.linkedin.com/in/taewook-kwon