Intelligent storage unit virtual debugging system and method

Abstract

The invention discloses an intelligent storage unit virtual debugging system and method. The method comprises the following steps: constructing an intelligent storage unit 3D model; simulating a running tool and a running environment of the 3D model of the intelligent storage unit, and constructing a digital twin model of the intelligent storage unit; a virtual PLC controller is generated, the virtual PLC controller is connected with the digital twinborn model of the intelligent storage unit, virtual debugging is carried out on the digital twinborn model, the virtual PLC controller is provided with a control program which is the same as that of a real PLC controller during operation, and the control program is written based on the actual movement condition of the real intelligent storage unit. Simulation and virtual debugging are carried out on the intelligent storage unit through the digital twinning technology, problems are found in time, the debugging period is shortened, the shutdown time is shortened, and the cost is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of material storage of intelligent storage units, and in particular relates to a virtual debugging system and method for intelligent storage units. Background Art

[0002] Intelligent storage units play an important role in the field of intelligent manufacturing in various industries. Intelligent storage units are a type of equipment that automatically stores goods, saves labor, and has high work efficiency. They are mainly composed of stackers, pallets, shelves, etc. Their application areas involve many industries, such as processing and manufacturing, automobile manufacturing, medical fields, and retail industries. Due to the complexity of the stored materials and their different shapes, and the storage of materials is completed by stackers, managers cannot directly understand the storage situation of materials and cannot intuitively understand the implementation conditions of stackers, which may cause material storage errors and inconvenient management. Moreover, debugging is performed after the equipment is installed, which increases the debugging time and cost. In the design process of automation equipment, the design process mainly goes through the stages of conceptual design, mechanical design, electrical design, and software design. The independence of each development stage is relatively strong, and it is basically impossible to achieve parallel design of mechanical structure and control system. Moreover, the process and control complexity of such equipment are relatively high, and on-site actual machine debugging is very difficult. Summary of the invention

[0003] In order to solve the above technical problems, the present invention proposes a virtual debugging system and method for an intelligent storage unit, which simulates and virtually debugs the intelligent storage unit through digital twin technology to timely discover problems, shorten the debugging cycle, reduce downtime, and reduce costs.

[0004] On the one hand, to achieve the above-mentioned purpose, the present invention provides a virtual debugging system for an intelligent storage unit, comprising: a 3D model construction module, an intelligent storage unit digital twin model construction module, a virtual PLC module, a virtual debugging environment construction module, and a human-machine interface module HMI;

[0005] The 3D model building module is used to build a 3D model of the intelligent storage unit;

[0006] A digital twin model construction module for an intelligent storage unit, which is used to simulate the operating tools and operating environment of the 3D model of the intelligent storage unit to construct a digital twin model of the intelligent storage unit;

[0007] The virtual PLC module is used to generate a virtual PLC controller, wherein the virtual PLC controller is installed with the same control program as the real PLC controller when running, and the virtual PLC controller is connected to the intelligent storage unit digital twin model construction module to perform virtual debugging on the digital twin model;

[0008] The virtual debugging environment building module is used to establish communication with the virtual PLC controller, complete device configuration, write a PLC program according to the movement of the stacker of the intelligent storage unit, and define a PLC variable table;

[0009] The human-machine interface module HMI is used to simulate the operator panel, test and optimize the operating concepts or interfaces that are already in the engineering stage, associate with relevant signals in the PLC program, and control the start and stop of the virtual commissioning movement.

[0010] Optionally, the 3D model building module includes: a 3D modeling unit, a model processing unit, and a model exporting unit.

[0011] The three-dimensional modeling unit is used to construct a three-dimensional geometric model of the intelligent storage unit according to the relationship between the components of the intelligent storage unit;

[0012] The model processing unit is used to perform lightweight processing on the three-dimensional geometric model to obtain the 3D model of the intelligent storage unit;

[0013] The model export unit is used to verify and convert the 3D model of the intelligent storage unit and import it into the digital twin model construction module of the intelligent storage unit.

[0014] Optionally, the intelligent storage unit digital twin model construction module includes: a motion mechanism setting unit, a fixture definition unit, and a sensor definition unit, wherein the motion mechanism setting unit is used to simulate the movement of the stacker in the XYZ direction;

[0015] The fixture definition unit is used to simulate the installation of the fixture on the stacker;

[0016] The defined sensor unit is used to simulate the type and installation environment of the sensor.

[0017] Optionally, the intelligent storage unit digital twin model construction module also includes an intelligent object creation unit, a simulation sequence definition unit, a signal creation unit and a communication unit;

[0018] The intelligent object creation unit is used to create the logic blocks required for the operation of the stacker, the input interface and the output interface of the logic blocks;

[0019] The defined simulation sequence unit is used to control the execution sequence of the stacker based on time or event sequence;

[0020] The signal creation unit is used to automatically generate signals through automatic mapping signals of smart objects, and place the signals in a signal viewer;

[0021] The communication unit is used to connect the intelligent storage unit digital twin model construction module and the virtual PLC module to realize virtual debugging of the intelligent storage unit 3D model.

[0022] Optionally, the process of defining the simulation sequence unit to control the execution sequence of the stacker based on time or event sequence includes position control and speed control.

[0023] Optionally, the virtual debugging environment building module includes a communication connection unit and a PLC program writing unit:

[0024] The communication connection unit is used to establish communication with the smart storage unit digital twin model construction module;

[0025] The PLC program writing unit is used to write the PLC program according to the actual movement of the intelligent storage unit, and set the data type and signal address of the signal in the program and add it to the PLC variable table and monitoring table.

[0026] Optionally, the data type and signal address of the signal in the program are consistent with the signal type and address in the digital twin model construction module of the intelligent storage unit.

[0027] On the other hand, to achieve the above-mentioned purpose, the present invention also provides a method for virtual commissioning of an intelligent storage unit, comprising: constructing a 3D model of the intelligent storage unit;

[0028] Simulating the operating tools and operating environment of the 3D model of the intelligent storage unit to build a digital twin model of the intelligent storage unit;

[0029] Generate a virtual PLC controller, connect the virtual PLC controller to the digital twin model of the intelligent storage unit, and virtually debug the digital twin model, wherein the virtual PLC controller is installed with the same control program as the real PLC controller when running, and the control program is written based on the actual movement of the real intelligent storage unit.

[0030] Optionally, constructing the 3D model of the intelligent storage unit includes: constructing a 3D geometric model of the intelligent storage unit according to the mutual relationship between the components of the intelligent storage unit, wherein the mutual relationship includes: the matching and constraint relationship between the independent components;

[0031] The three-dimensional geometric model is lightweighted to obtain the 3D model of the intelligent storage unit, wherein the lightweighting process includes extraction, reorganization, and surface reduction to achieve simplification of the geometric model.

[0032] Optionally, simulating the operating tools and operating environment of the 3D model of the intelligent storage unit to construct the digital twin model of the intelligent storage unit includes:

[0033] Set the movement of the stacker in the XYZ direction;

[0034] installing a clamp on the stacker;

[0035] Set the type of sensor, installation environment, and simulate the installation of the sensor;

[0036] Creating the logic blocks, input interfaces and output interfaces of the logic blocks required for the operation of the stacker;

[0037] Controlling the execution sequence of the stacker based on time or event sequence;

[0038] Automatically map signals through smart objects, automatically generate signals, and place them in the signal viewer.

[0039] Technical effect of the invention: The present invention discloses a virtual debugging system and method for an intelligent storage unit. By adding the same motion mechanism, sensor, motion logic editing and simulation sequence as the physical equipment, and the same PLC program as the physical equipment to the digital twin model of the intelligent storage unit, the model has realistic physical properties and can have a motion model under the physical system. Before the equipment is installed, the equipment is simulated and tested for multiple times in a virtual environment according to the design results. The equipment can be improved based on the test results, most of the faults and errors can be solved, the R&D quality and on-site debugging efficiency can be improved, the debugging cycle can be shortened, and the cost can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The drawings constituting a part of the present application are used to provide a further understanding of the present application. The illustrative embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0041] Figure 1 1 is a three-dimensional schematic diagram of an intelligent storage unit according to an embodiment of the present invention, wherein 1 is a stacker, 2 is a pallet, 3 is a material rack, and 4 is a box body of the intelligent storage unit;

[0042] Figure 2 This is a structural schematic diagram of a virtual debugging system for an intelligent storage unit according to an embodiment of the present invention;

[0043] Figure 3 The present invention is a flowchart of a virtual debugging method for an intelligent storage unit according to an embodiment of the present invention. DETAILED DESCRIPTION

[0044] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0045] It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and that, although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0046] like Figure 1 As shown, the intelligent storage unit of the embodiment of the present invention includes:

[0047] It consists of a stacker 1, a pallet 2, a material rack 3, and an intelligent storage unit box 4. A servo drive and a PLC control module are installed in the intelligent storage unit box 4. Two different types of pallets, raw material pallets and finished product pallets, are placed on the three-dimensional material rack of the storage. The stacker 1 and the material rack 3 are installed on the intelligent storage unit box 4. The stacker 1 has three movement directions: X, Y, and Z. The stacker 1 is equipped with a grab plate and a photoelectric sensor on the Y-axis moving table, which can detect the presence or absence of the pallet 2, and is supported and guided by a guide rail to realize the extraction / release of the pallet 2. The PLC control module receives signals to control the movement of the servo motor. The servo motor is driven by the PLC to drive the stacker to realize the movement in the three directions of X, Y, and Z, thereby realizing the pallet in and out of the warehouse. The movement of each axis is driven by an independent servo motor.

[0048] like Figure 2 As shown, in this embodiment, a virtual debugging system for an intelligent storage unit is provided, including:

[0049] 3D model construction module, intelligent storage unit digital twin model construction module, virtual PLC module, virtual debugging environment construction module, human-machine interface module HMI;

[0050] The 3D model building module is used to build a 3D model of the intelligent storage unit;

[0051] A digital twin model construction module for an intelligent storage unit, which is used to simulate the operating tools and operating environment of the 3D model of the intelligent storage unit to construct a digital twin model of the intelligent storage unit;

[0052] The virtual PLC module is used to generate a virtual PLC controller, wherein the virtual PLC controller is installed with the same control program as the real PLC controller when running, and the virtual PLC controller is connected to the intelligent storage unit digital twin model construction module to perform virtual debugging on the digital twin model;

[0053] The virtual debugging environment building module is used to establish communication with the virtual PLC controller, complete device configuration, write a PLC program according to the movement of the stacker of the intelligent storage unit, and define a PLC variable table;

[0054] The human-machine interface module HMI is used to simulate the operator panel, test and optimize the operating concepts or interfaces that are already in the engineering stage, associate with relevant signals in the PLC program, and control the start and stop of the virtual commissioning movement.

[0055] Furthermore, the 3D model building module includes: a 3D modeling unit, a model processing unit, a model exporting unit,

[0056] The three-dimensional modeling unit is used to construct a three-dimensional geometric model of the intelligent storage unit according to the relationship between the components of the intelligent storage unit;

[0057] The model processing unit is used to perform lightweight processing on the three-dimensional geometric model to obtain the 3D model of the intelligent storage unit;

[0058] The model export unit is used to verify and convert the 3D model of the intelligent storage unit and import it into the digital twin model construction module of the intelligent storage unit.

[0059] Furthermore, the digital twin model building module of the intelligent storage unit includes: a motion mechanism setting unit, a fixture definition unit, and a sensor definition unit, wherein the motion mechanism setting unit is used to simulate the movement of the stacker in the XYZ direction;

[0060] The fixture definition unit is used to simulate the installation of the fixture on the stacker;

[0061] The defined sensor unit is used to simulate the type and installation environment of the sensor.

[0062] Furthermore, the intelligent storage unit digital twin model construction module also includes an intelligent object creation unit, a simulation sequence definition unit, a signal creation unit and a communication unit;

[0063] The intelligent object creation unit is used to create the logic blocks required for the operation of the stacker, the input interface and the output interface of the logic blocks;

[0064] The defined simulation sequence unit is used to control the execution sequence of the stacker based on time or event sequence;

[0065] The signal creation unit is used to automatically generate signals through automatic mapping signals of smart objects, and place the signals in a signal viewer;

[0066] The communication unit is used to connect the intelligent storage unit digital twin model construction module and the virtual PLC module to realize virtual debugging of the intelligent storage unit 3D model.

[0067] Furthermore, the process of defining the simulation sequence unit to control the execution sequence of the stacker based on time or event sequence includes position control and speed control.

[0068] Furthermore, the virtual debugging environment building module includes a communication connection unit and a PLC program writing unit:

[0069] The communication connection unit is used to establish communication with the smart storage unit digital twin model construction module;

[0070] The PLC program writing unit is used to write the PLC program according to the actual movement of the intelligent storage unit, and set the data type and signal address of the signal in the program and add it to the PLC variable table and monitoring table.

[0071] Furthermore, the data type and signal address of the signal in the program are consistent with the signal type and address in the digital twin model construction module of the intelligent storage unit.

[0072] Specific:

[0073] (1) Based on the coordination and constraint relationships between the independent components of the intelligent storage unit, the three-dimensional geometric model of the intelligent storage unit is constructed using three-dimensional modeling software.

[0074] (2) The model is lightweighted while ensuring that key information is intact, model accuracy, and usage accuracy are met. This mainly includes extraction, reorganization, and surface reduction to simplify the geometric model. The 3D model can also be modified according to the material color of the actual physical model to ensure that the 3D model and the physical device are highly consistent.

[0075] (3) Convert the constructed 3D model into .JT format and export it, and place the exported model in a folder with a .cojt suffix.

[0076] After the geometric model is created, processed and format converted, the model is imported into the ProcessSimulate simulation platform.

[0077] The Process Simulate simulation platform is used to receive the constructed 3D model, set the motion mechanism, define the fixture, define the sensor, and create the smart object for the 3D model in turn, complete the arrangement of the simulation sequence according to the actual working conditions of the smart storage unit, and establish the communication between the virtual PLC software S7-PLCSIMAdvanced and the model. Specifically:

[0078] (1) Set the movement of the corresponding mechanism of the stacker in the XYZ direction. Select the stacker, select the base or do not select any parts as the reference system. The name can be defaulted to lnk1. Select the column part of the stacker as lnk2, lnk1 as the reference system of lnk2, drag lnk1 to lnk2, define joint j1, set the joint type to translation, select two points in the X direction on the model in turn, set the movement direction to complete the movement of the stacker in the X direction. The same method can be used to set the motion joints in the other two directions of the stacker. The motion parts select the motion structure of the corresponding direction of the stacker.

[0079] (2) In Process Simulate, the forceless effect requires the use of fixtures and sensors to lift the object. In the tool definition dialog box, set the component that lifts the pallet as a fixture, and install the fixture on the stacker according to the fixture's reference coordinate system and working coordinate system.

[0080] (3) Set the sensor name, size, etc. in the Process Simulate control toolbar. The detection range can be selected as the default. In the present invention, the detection object is the pallet. Move the sensor to the corresponding position and install the sensor on the stacker or the component on the shelf that needs the sensor.

[0081] (4) Select the stacker, create a logic block, define the input and output interfaces, parameters, and motion, including the input interface definition of the logic block, define the motion enable and target position signals in three directions, click Create Signal, and create the corresponding signal; define the output signal of the logic block, define and create the actual position signal in three directions, and then set the value of the stacker's actual position signal in the stacker logic block exit; define the position parameters of the stacker in three directions and associate them with the corresponding joints; define the motion behavior, and the motion speed, acceleration, and deceleration can be freely set to control the motion speed of the simulation model. The input interface of the logic block corresponds to the output interface of the PLC, and the output interface of the logic block corresponds to the input interface of the PLC. In the same way, the fixture logic block can be set, mainly through the sensor signal to control the fixture to achieve the clamping and loosening of the pallet.

[0082] (5) The intelligent storage unit controls the execution sequence of the stacker based on time or event sequence, including position control and speed control.

[0083] (6) Through the automatic mapping of signals by smart objects, signals are automatically generated and placed in the signal viewer. The data type and address of the signal must be consistent with the signal type and address defined in TIA Portal.

[0084] (7) Set up the PLC connection in Process Simulate, add the PLCSIMAdvanced connection, search for the created virtual PLC controller to complete the communication connection between S7-PLCSIM Advanced and Process Simulate, and then perform virtual debugging of the 3D model through the PLC program.

[0085] The virtual PLC technology module is a technology based on configuration software and virtual PLC to realize PLC control in a virtual environment, specifically:

[0086] Start the S7-PLCSIMAdvanced software, enter the signal name, select the S7-1500 series PLC, generate a virtual PLC controller, select the CPU1511-1PN series PLC device in the TIA Portal to complete the communication with PLCSIM Advanced, download the written PLC program to the virtual PLC controller, and connect the virtual PLC controller to the Process Simulate simulation platform to perform virtual debugging of the digital twin model.

[0087] TIAPortal environment construction and PLC writing module are used to add CPU1511-1PN series PLC controller, establish communication between TIAPortal and S7-PLCSIMAdvanced, complete device configuration, write PLC program according to the movement of intelligent storage unit stacker, and define variable table.

[0088] (1) Start the S7-PLCSIMAdvanced software, select the S7-1500 type PLC, start the virtual PLC controller, start the TIA Portal software, add the CPU1511-1PN series PLC controller, start the CPU, and click Download to Device to complete the communication with S7-PLCSIMAdvanced.

[0089] (2) Write a PLC program based on the actual motion of the intelligent storage unit, set the data type and signal address of the signal in the program, and add the signal to the PLC variable table and monitoring table. The data type and address of the signal are consistent with the signal type and address in ProcessSimulate. Download the written PLC program to the virtual PLC again. Drive the motion components of the 3D model in the simulation platform to complete the set process simulation action.

[0090] HMI human machine interface module, used to simulate the operator panel in order to test and optimize the operating concept or interface that is already in the engineering stage. Associated with the relevant signals in the PLC program, the HMI controls the start and stop of the virtual commissioning movement.

[0091] Specifically, the present invention example is based on the HMI model KTP700 Basic, builds and adds a general control interface, a manual operation screen, and a parameter setting screen, which can realize manual / automatic switching, start, and stop operations.

[0092] like Figure 3 As shown, in this embodiment, a method for virtual debugging of an intelligent storage unit is provided, comprising the following steps: constructing a 3D model of the intelligent storage unit;

[0093] Simulating the operating tools and operating environment of the 3D model of the intelligent storage unit to build a digital twin model of the intelligent storage unit;

[0094] Generate a virtual PLC controller, connect the virtual PLC controller to the digital twin model of the intelligent storage unit, and virtually debug the digital twin model, wherein the virtual PLC controller is installed with the same control program as the real PLC controller when running, and the control program is written based on the actual movement of the real intelligent storage unit.

[0095] Further, constructing the 3D model of the intelligent storage unit includes: constructing a 3D geometric model of the intelligent storage unit according to the mutual relationship between the components of the intelligent storage unit, wherein the mutual relationship includes: the cooperation and constraint relationship between the independent components;

[0096] The three-dimensional geometric model is lightweighted to obtain the 3D model of the intelligent storage unit, wherein the lightweighting process includes extraction, reorganization, and surface reduction to achieve simplification of the geometric model.

[0097] Furthermore, simulating the operating tools and operating environment of the 3D model of the intelligent storage unit to construct a digital twin model of the intelligent storage unit includes:

[0098] Set the movement of the stacker in the XYZ direction;

[0099] installing a clamp on the stacker;

[0100] Set the type of sensor, installation environment, and simulate the installation of the sensor;

[0101] Creating the logic blocks, input interfaces and output interfaces of the logic blocks required for the operation of the stacker;

[0102] Controlling the execution sequence of the stacker based on time or event sequence;

[0103] Automatically map signals through smart objects, automatically generate signals, and place them in the signal viewer.

[0104] The specific implementation process of the method of the present invention includes:

[0105] S1. Complete the 3D modeling of the intelligent storage unit in the 3D model building module, convert the 3D model into .JT format after lightweight processing and import it into the Process Simulate simulation platform.

[0106] S1.1: Based on the coordination and constraint relationship between the independent components of the intelligent storage unit, the three-dimensional geometric model of the intelligent storage unit is constructed through three-dimensional modeling software.

[0107] S1.2: The three-dimensional model of the intelligent storage unit is lightweighted while ensuring that key information is intact, the model is accurate, and the usage accuracy is met. This mainly includes extraction, reorganization, and surface reduction to simplify the geometric model. The three-dimensional model can also be modified according to the material color of the actual physical model to ensure that the three-dimensional model and the physical equipment are highly consistent.

[0108] S1.3: Convert the format of the constructed 3D model into .JT format and export it. Place the exported model in a folder with the suffix .cojt and import the model into the Process Simulate simulation platform.

[0109] S2, Process Simulate simulation platform establishes the mechanism motion joints for the 3D model, defines sensors, creates stacker logic blocks, creates signals and assigns signal addresses, and defines simulation sequences. Specifically, it includes:

[0110] S2.1: Select the stacker, select the base or do not select any parts as the reference system, the name can be defaulted to lnk1. Select the column part of the stacker as lnk2, lnk1 as the reference system of lnk2, drag lnk1 to lnk2, define joint j1, set the joint type to translation, select two points in the X direction on the model in turn, set the movement direction to complete the movement of the stacker in the X direction. The same method can be used to set the motion joints in the other two directions of the stacker, and the motion parts select the motion structure of the corresponding direction of the stacker.

[0111] S2.2: In the tool definition dialog box, set the component that lifts the pallet as a fixture, and install the fixture on the stacker according to the fixture's reference coordinate system and work coordinate system, and use the fixture and sensor to lift the object.

[0112] S2.3: Set the sensor name, size, etc. in the Process Simulate control toolbar. The detection range can be selected as the default. Move the sensor to the corresponding position and install the sensor on the parts that need the sensor on the stacker or shelf.

[0113] S2.4: Select the stacker, create the input interface definition of the logic block, define the motion enable and target position signals in three directions, click Create Signal to create the corresponding signal; define the output signal definition of the logic block, define and create the actual position signal in three directions, and then set the value of the stacker actual position signal in the stacker logic block exit; define the position parameters of the stacker in three directions and associate them with the corresponding joints; define the motion behavior, the motion speed, acceleration, and deceleration can be freely set to control the motion speed of the simulation model. The input interface of the logic block corresponds to the output interface of the PLC, and the output interface of the logic block corresponds to the input interface of the PLC. In the same way, the fixture logic block can be set, mainly through the sensor signal to control the fixture to achieve the clamping and loosening of the pallet.

[0114] S2.5: The execution sequence of the stacker crane is controlled based on time or event sequence through the intelligent storage unit, including position control and speed control.

[0115] S2.6: Through the automatic mapping of signals by smart objects, signals are automatically generated and placed in the signal viewer. The data type and address of the signal must be consistent with the signal type and address defined in TIA Portal. Through the movement of all moving components, the digital twin model completes the complete process action, mainly by using virtual PLC technology to establish a connection with the virtual model PLC program, and using PLC signals to drive the model to run

[0116] S3. Start the S7-PLCSIMAdvanced software, enter the signal name, select the same PLC device type as in TIAPortal, and start the virtual PLC controller.

[0117] S4. Complete the construction of the virtual debugging environment in TIA Portal, write the PLC program according to the control of the intelligent storage unit defined in Process Simulate, and establish communication with S7-PLCSIMAdvanced. Specifically include:

[0118] S4.1: After starting TIA Portal, add the CPU1511-1PN series controller and click Download to Device to complete the communication with S7-PLCSIMAdvanced.

[0119] S4.2: Write the PLC program according to the actual movement of the intelligent storage unit, set the data type and signal address of the signal in the program, and add the signal to the PLC variable table and monitoring table. The data type and address of the signal are consistent with the signal type and address in ProcessSimulate.

[0120] S5. Set up PLC external connection in Process Simulate, add PLCSIMAdvanced connection, and search for the created S7-PLCSIM Advanced virtual PLC controller to complete the communication connection with Process Simulate.

[0121] S6. By starting the simulation command in Process Simulate, downloading the PLC program to the virtual PLC controller in TIA Portal, enabling monitoring after going online, and starting the simulation in the HMI human-machine interface, the mechanical structure, control system and movement of the intelligent storage unit can be observed in real time, and displayed and simulated in a virtual environment. Specifically:

[0122] In the TIAPorta software, add the data type and signal address of the signal in the PLC program to the PLC variable table and monitoring table. The variable address must be consistent with the signal address in Process Simulate. Write the PLC program and download it to the virtual PLC controller. Select the production line simulation mode in Process Simulate, start the simulation, go online in TIAPorta, enable monitoring, and change the start signal start to 1 to realize the automatic operation of the virtual stacker moving, picking up pallets, and placing pallets. In the HMI human-machine interface, associate buttons, signal lights, etc. with relevant signals in the PLC program to realize the start and stop of the virtual debugging movement controlled by the HMI.

[0123] S7. Observe whether the digital twin model meets the requirements in each link.

[0124] S8. If there is a problem in the process simulation, modify the 3D model or PLC program and repeat step S5. If the simulation meets the process simulation requirements, the 3D model is determined to be qualified.

[0125] The present invention discloses a virtual debugging system and method for an intelligent storage unit. By adding the same motion mechanism, sensor, motion logic editing and simulation sequence as the physical equipment, and the same PLC program as the physical equipment to the digital twin model of the intelligent storage unit, the model has realistic physical characteristics and can have a motion model under the physical system. Before the equipment is installed, the equipment is simulated and tested multiple times in a virtual environment according to the design results. The equipment can be improved based on the test results, most of the faults and errors can be solved, the R&D quality and on-site debugging efficiency can be improved, the debugging cycle can be shortened, and the cost can be reduced.

[0126] The above are only preferred specific implementations of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. An intelligent storage unit virtual commissioning system, characterized in that: include: 3D model construction module, intelligent storage unit digital twin model construction module, virtual PLC module, virtual debugging environment construction module, human-machine interface module HMI; The 3D model building module is used to build a 3D model of the intelligent storage unit; A digital twin model construction module for an intelligent storage unit, which is used to simulate the operating tools and operating environment of the 3D model of the intelligent storage unit to construct a digital twin model of the intelligent storage unit; The virtual PLC module is used to generate a virtual PLC controller, wherein the virtual PLC controller is installed with the same control program as the real PLC controller when running, and the virtual PLC controller is connected to the intelligent storage unit digital twin model construction module to perform virtual debugging on the digital twin model; The virtual debugging environment building module is used to establish communication with the virtual PLC controller, complete device configuration, write a PLC program according to the movement of the stacker of the intelligent storage unit, and define a PLC variable table; The human-machine interface module HMI is used to simulate the operator panel, test and optimize the operating concepts or interfaces that are already in the engineering stage, associate with relevant signals in the PLC program, and control the start and stop of the virtual commissioning movement.

2. The intelligent storage unit virtual commissioning system according to claim 1, characterized in that: The 3D model building module includes: a 3D modeling unit, a model processing unit, and a model exporting unit. The three-dimensional modeling unit is used to construct a three-dimensional geometric model of the intelligent storage unit according to the relationship between the components of the intelligent storage unit; The model processing unit is used to perform lightweight processing on the three-dimensional geometric model to obtain the 3D model of the intelligent storage unit; The model export unit is used to verify and convert the 3D model of the intelligent storage unit and import it into the digital twin model construction module of the intelligent storage unit.

3. The intelligent storage unit virtual commissioning system according to claim 1, characterized in that: The digital twin model building module of the intelligent storage unit includes: a motion mechanism setting unit, a fixture definition unit, and a sensor definition unit, wherein the motion mechanism setting unit is used to simulate the movement of the stacker in the XYZ direction; The fixture definition unit is used to simulate the installation of the fixture on the stacker; The defined sensor unit is used to simulate the type and installation environment of the sensor.

4. The intelligent storage unit virtual commissioning system according to claim 1 or 3, characterized in that: The smart storage unit digital twin model construction module also includes a smart object creation unit, a simulation sequence definition unit, a signal creation unit and a communication unit; The intelligent object creation unit is used to create the logic blocks required for the operation of the stacker, the input interface and the output interface of the logic blocks; The defined simulation sequence unit is used to control the execution sequence of the stacker based on time or event sequence; The signal creation unit is used to automatically generate a signal through automatic mapping of the signal by the smart object, and place the signal in the signal viewer; The communication unit is used to connect the intelligent storage unit digital twin model construction module and the virtual PLC module to realize virtual debugging of the intelligent storage unit 3D model.

5. The intelligent storage unit virtual commissioning system according to claim 4, characterized in that: The process of defining the simulation sequence unit to control the execution sequence of the stacker based on time or event sequence includes position control and speed control.

6. The intelligent storage unit virtual commissioning system according to claim 1, characterized in that: The virtual debugging environment building module includes a communication connection unit and a PLC program writing unit: The communication connection unit is used to establish communication with the smart storage unit digital twin model construction module; The PLC program writing unit is used to write the PLC program according to the actual movement of the intelligent storage unit, and set the data type and signal address of the signal in the program and add it to the PLC variable table and monitoring table.

7. The intelligent storage unit virtual commissioning system according to claim 6, characterized in that: The data type and signal address of the signal in the program are consistent with the signal type and address in the digital twin model construction module of the intelligent storage unit.

8. A method applied to the intelligent storage unit virtual commissioning system according to any one of claims 1 to 7, characterized in that: The following steps are involved: Build a 3D model of the intelligent storage unit; Simulating the operating tools and operating environment of the 3D model of the intelligent storage unit to build a digital twin model of the intelligent storage unit; Generate a virtual PLC controller, connect the virtual PLC controller to the digital twin model of the intelligent storage unit, and virtually debug the digital twin model, wherein the virtual PLC controller is installed with the same control program as the real PLC controller when running, and the control program is written based on the actual movement of the real intelligent storage unit.

9. The method for virtual commissioning of an intelligent storage unit according to claim 8, characterized in that: Constructing the 3D model of the intelligent storage unit includes: constructing a 3D geometric model of the intelligent storage unit according to the mutual relationship between the components of the intelligent storage unit, wherein the mutual relationship includes: the cooperation and constraint relationship between the independent components; The three-dimensional geometric model is lightweighted to obtain the 3D model of the intelligent storage unit, wherein the lightweighting process includes extraction, reorganization, and surface reduction to achieve simplification of the geometric model.

10. The method for virtual commissioning of an intelligent storage unit according to claim 8, characterized in that: The operation tools and the operation environment of the 3D model of the intelligent storage unit are simulated to construct the digital twin model of the intelligent storage unit, including: Set the movement of the stacker in the XYZ direction; installing a clamp on the stacker; Set the type of sensor, installation environment, and simulate the installation of the sensor; Creating the logic blocks, input interfaces and output interfaces of the logic blocks required for the operation of the stacker; Controlling the execution sequence of the stacker based on time or event sequence; Automatically map signals through smart objects, automatically generate signals, and place them in the signal viewer.

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