Virtual simulation platform

Abstract

The invention provides a virtual simulation platform which comprises a protocol analysis device which is connected with a PLC and simulation software, receives first data information issued by the PLC through an industrial bus, converts the first data information into a format meeting the input requirement of the simulation software, obtains second data information and issues the second data information to the simulation software; the simulation software receives the second data information issued by the protocol analysis device and drives the 3D model to act and display according to the second data information, and meanwhile, the simulation software performs virtual simulation according to the simulation object and the second data information, generates third data information of the simulation object on an application level and sends the third data information to the protocol analysis device; and after being processed by the protocol analysis device, the data is sent to the PLC. Through the virtual simulation platform combining the protocol analysis device and the simulation software, the two problems of PLC brand compatibility and IO simulation are thoroughly solved, debugging work is truly preposed, a debugged program can be directly used on actual equipment, the construction period is shortened, and the delivery risk is reduced.

Description

Technical Field

[0001] The present application relates to the technical field of virtual simulation of non-standard equipment, and in particular, to a virtual simulation platform. Background Art

[0002] In the process of developing non-standard equipment, conceptual design, detailed design, drawing, processing, PLC program writing, assembly and debugging are the conventional processes. According to this process, mechanical design and electrical design can only verify whether the overall motion rhythm of the equipment meets the design after processing and assembly. If it is found at this time: insufficient stroke, beat does not meet the requirements, actual movement and design movement are inconsistent, movement collision and other low-level errors, it is necessary to start from scratch, resulting in serious waste of material and labor costs. If the motion rhythm of the equipment can be checked, verified and optimized before drawing and processing, the manufacturing cycle can be shortened and material and labor costs can be reduced.

[0003] At present, virtual debugging of non-standard equipment can basically realize the simulation and debugging of equipment in a virtual environment before the actual manufacturing and integration of the production line, such as checking the equipment layout, mechanism interference, and the operation of the PLC program. Through virtual debugging, problems can be discovered in advance and risks can be reduced. However, the common problems of simulation software on the market are:

[0004] 1. Compatibility issues: All PLC simulation software launched by PLC manufacturers are based on their own programming software development and are only compatible with their own single brand, so they are not very practical.

[0005] 2. IO simulation problem: The simulation of IO signals cannot be realized. Without actual sensor feedback signals, the simulation software cannot collect IO signals. There are great limitations for virtual debugging of the program, and it is impossible to simulate the complete logic. Summary of the invention

[0006] In view of the defects in the prior art, the purpose of this application is to provide a virtual simulation platform.

[0007] Specifically, the present application provides a virtual simulation platform, including: a protocol parsing device and simulation software, wherein:

[0008] The protocol analysis device is connected to the PLC and the simulation software, receives the first data information sent from the PLC through the industrial bus, converts the first data information into a format that meets the input requirements of the simulation software, obtains the second data information and sends it to the simulation software; the first data information and the second data information are data information required for the simulation object simulation;

[0009] The simulation software receives the second data information sent by the protocol parsing device, and drives the 3D model to move and display according to the second data information. At the same time, the simulation software performs virtual simulation according to the simulation object and the second data information, generates the third data information of the simulation object at the application level, and sends it to the protocol parsing device. After processing, the protocol parsing device sends it to the PLC.

[0010] The first data information and the second data information both include one or more of the position, speed, acceleration, and IO signal data of each axis;

[0011] The third data information includes one or more of IO data, position feedback data, and alarm information data.

[0012] Furthermore, the protocol analysis device comprises:

[0013] The protocol setting unit is used to set the industrial bus protocol currently used to connect to the PLC;

[0014] The data processing unit is used to receive the first data information sent by the PLC through the set industrial bus protocol, and send it to the simulation software after processing, drive the action of the three-dimensional model in the simulation software, and perform virtual simulation; at the same time, it also receives the third data information sent from the simulation software, and sends it to the PLC after processing.

[0015] Furthermore, the simulation software includes:

[0016] Model import unit, used to import 3D models in common formats and configure model parameters;

[0017] A data mapping unit, used for mapping the address of the data sent by the protocol analysis device with the three-dimensional model;

[0018] A data receiving unit, configured to receive the second data information sent by the protocol parsing device;

[0019] A 3D visualization unit, used to drive the 3D model to move and display according to the received second data information;

[0020] IO setting unit, used for configuration and automatic operation of IO signal trigger logic;

[0021] The data sending unit sends the third data information to the protocol parsing device according to the set logic and motion state.

[0022] Further, the simulation software also includes a beat statistics unit, and the beat statistics unit includes beat interval designation and beat statistics display;

[0023] The beat interval designation is used to select the IO signal and state at the beat start point and the IO signal and state at the beat end point to be monitored;

[0024] The beat statistics display is used to periodically record the data selected by the beat interval and perform statistics display according to the specified data start time and status.

[0025] Further, the simulation software also includes a collision statistics unit, and the collision statistics unit includes collision statistics display and collision fault feedback;

[0026] The collision statistics display is used to count and display the collision point information generated when the model joint moves according to the received axis position information;

[0027] The collision fault feedback is used to feed back the collision fault information generated when the model joint moves according to the received axis position information to the protocol analysis device.

[0028] Furthermore, the IO setting unit is used to perform automatic triggering settings of IO, specify the state of the IO signal to be set, select the triggering conditions, including IO data, servo position data and time delay data, and set the conditions in logical combinations of AND, OR and NOT to ensure that the IO signal is automatically triggered according to the set conditions.

[0029] Compared with the prior art, the present invention has at least one of the following beneficial effects:

[0030] 1. This application can use the platform for virtual simulation of non-standard equipment using PLCs of various mainstream brands, pre-engineering mechanical design, electrical design, and equipment debugging, reducing changes and shortening the debugging cycle.

[0031] 2. This application uses the architecture of protocol parsing device + simulation software to run real control programs and logic, which can conduct large-scale testing and reduce delivery risks and subsequent maintenance costs.

[0032] 3. This application designs a universal simulation platform that supports all mainstream brands of PLCs and solves the problem of being unable to simulate IO during virtual debugging. It truly puts debugging work in advance so that debugged programs can be directly used on actual equipment, thus shortening the construction period. Through virtual debugging, mechanical, electrical, and process engineering can work in parallel, so that mechanical engineers can find problems in advance and reduce changes, electrical engineers can test program completeness and shorten the debugging cycle, and process engineers can find process problems in advance and reduce delivery risks. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Other features, objects and advantages of the present application will become more apparent by reading the detailed description of non-limiting embodiments with reference to the following drawings:

[0034] Figure 1 This is a block diagram of a virtual simulation platform according to an embodiment of the present application.

[0035] Figure 2 This is a structural diagram of a virtual simulation platform according to an embodiment of the present application.

[0036] Figure 3 This is a structural diagram of a detection device according to an embodiment of the present application. DETAILED DESCRIPTION

[0037] The present application is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present application, but do not limit the present application in any form. It should be noted that, for those of ordinary skill in the art, several variations and improvements can also be made without departing from the concept of the present application. These all belong to the protection scope of the present application.

[0038] It should be understood that the terms "first", "second", etc. in the following embodiments are used to distinguish different objects rather than to describe a specific order. The terms "include" and "comprise" used indicate the presence of the described features, wholes, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or their collections.

[0039] Reference Figure 1 As shown, a virtual simulation platform of an embodiment of the present application includes: a protocol parsing device and simulation software. The protocol parsing device connects the PLC and the simulation software, receives the first data information sent from the PLC through the industrial bus, converts the first data information into a format that meets the input requirements of the simulation software, obtains the second data information and sends it to the simulation software; the first data information and the second data information are the data information required for the simulation object simulation; the simulation software receives the second data information sent by the protocol parsing device, and drives the 3D model to move and display according to the second data information. At the same time, the simulation software performs virtual simulation according to the simulation object and the second data information, generates the third data information of the simulation object at the application level, and sends it to the protocol parsing device, and the protocol parsing device processes and sends it to the PLC.

[0040] Through the virtual simulation platform, the PLC program can be virtually debugged without connecting to the actual hardware device, which shortens the debugging cycle and improves the debugging efficiency. Through the dynamic display of the three-dimensional model in the virtual simulation platform and the architecture of the protocol parser + simulation software, the real control program and logic can be run to conduct large-scale testing, which can reduce the delivery risk and subsequent maintenance costs.

[0041] In the embodiment of the present application, the first data information and the second data information are data information required for the simulation of the simulation object, and the data information is determined specifically according to the simulation object and the required simulation purpose, wherein the first data information corresponds to the original relevant information of the simulation object, and the second data information corresponds to the data information that needs to meet the format requirements of the simulation software input, by converting the original first data information format into the format required by the simulation software, so that the entire platform can meet the simulation of data in any different formats, solve the two major problems of PLC brand compatibility and IO simulation, and greatly improve the scope of application of the platform. The third data information is generated according to the simulation object and the simulation requirements (including the logic and motion state of the simulation setting, action requirements, etc.) to generate specific application meaning data. For example, in some embodiments, when the position / speed of the simulation object needs to be simulated, the first data information and the second data information can both include one or more of the position, speed, acceleration, IO signal data, etc. of each axis; after the third data information is simulated, it can be embodied as one or more of IO data, position feedback data, alarm information data, etc. at the application level. Of course, in other embodiments, it can also be other data information, not limited to the above.

[0042] Specifically, first, the function of the protocol parsing device is to receive information from the PLC program, and receive at least one first data information sent from the PLC through the industrial bus, including but not limited to the position, speed, acceleration, IO signal and other data of each axis, and send it to the simulation software after processing. At the same time, the protocol parsing device is also responsible for feeding back the corresponding information to the PLC program to ensure that the PLC program can run automatically. Finally, the simulation software receives the data including but not limited to the position data of each axis and related data sent by the protocol parsing device, and drives the 3D model to move and display according to the above data; and drives the three-dimensional model to move according to these data information. At the same time, the simulation software sends including but not limited to IO signals and alarm information to the protocol parsing device according to the set logic and motion state. After the protocol parsing device processes, the data information processed by the protocol parsing device conforms to the PLC receiving format and is sent to the PLC.

[0043] In some possible embodiments, the protocol parsing device includes: a protocol setting unit, which is used to set the industrial bus protocol currently used to connect to the PLC; a data processing unit, which is used to receive the first data information sent by the PLC through the set industrial bus protocol, including but not limited to the position data and IO data of each axis, and send it to the simulation software after processing, drive the action of the three-dimensional model in the simulation software, and perform virtual simulation. At the same time, the third data information sent from the simulation software is also received, including IO data, position feedback data, alarm information and other data, and sent to the PLC after processing.

[0044] In this application, the protocol parsing device acts as an independent component, responsible for handling the communication and data conversion between the PLC and the simulation software, reducing the complexity of the system and the complexity of system maintenance and upgrades. Through accurate transmission and timely processing of data, the protocol parsing device improves the stability of the entire system and reduces system failures caused by data transmission errors or delays.

[0045] like Figure 2 As shown, specifically, the platform of the application adopts a system architecture of a protocol parser + simulation software, wherein the protocol parser is responsible for receiving PLC program information, processing and forwarding the received information, and feeding back corresponding information to the PLC program to ensure that the PLC program can be virtually debugged.

[0046] The simulation software is equipped with a model import unit, which loads the 3D model of the industrial automation system through the 3D engine. The loaded model is displayed in the simulation environment, and the corresponding functions are written. First, use the 3D engine (such as Unity, Unreal Engine, etc.) to load the pre-designed 3D model. After loading, the 3D engine renders the model to the screen to realize real-time display of the model. Users can observe the appearance and initial state of the model through the interface. Then, by writing the control function, the dynamic control of the model is realized.

[0047] In some specific embodiments, the simulation software includes: a model import unit, which is used to import a three-dimensional model in a universal format and configure model parameters; wherein the universal format includes but is not limited to URDF, STL, OBJ and FBX, and the model parameters include but are not limited to the motion type, motion axis and motion stroke; a data mapping unit, which is used to map the address of the data sent by the protocol parsing device with the corresponding relationship of the three-dimensional model; a data receiving unit, which is used to receive the second data information sent by the protocol parsing device, including but not limited to the position data of each axis and IO data; a 3D visualization unit, which is used to drive the action and display of the 3D model according to the received second data information, including the position data of each axis and IO data; an IO setting unit, which is used to configure and automatically run the IO signal trigger logic; a data sending unit, which sends third data information, including but not limited to IO signals, alarms and other information to the protocol parsing device according to the set logic and motion status.

[0048] Specifically, the simulation software first imports 3D models in various general formats, such as URDF, STL, OBJ and FBX, through the model import unit, and configures various parameters of the model, including motion type, motion axis and motion stroke. Then, the data mapping unit establishes a corresponding relationship between these 3D models and the data address sent by the protocol parsing device to ensure that the data can be accurately mapped to the corresponding model. Subsequently, the data receiving unit receives the data sent by the protocol parsing device, which includes but is not limited to the position data of each axis and IO data. After receiving the sent data, the 3D visualization unit will drive the 3D model to perform corresponding actions and displays according to the received data to achieve the effect of real-time simulation. At the same time, the IO setting unit is responsible for configuring the trigger logic and automatic operation rules of the IO signal to ensure that the IO signal in the simulation process can be triggered and responded according to the predetermined logic. Finally, the data sending unit sends the data including IO signals, alarms and other information back to the protocol parsing device according to the set logic and the current motion state to complete the entire simulation process.

[0049] Among them, the IO setting unit is used to perform automatic triggering settings of IO, specify the state of the IO signal to be set, select its triggering conditions, including but not limited to IO data, servo position data and time delay data, and set the conditions for logical combinations of AND, OR, and NOT to ensure that the IO signal is automatically triggered according to the set conditions.

[0050] In some specific embodiments, the simulation software further includes a data mapping unit for mapping the address of the data sent by the protocol parsing device with the three-dimensional model in a corresponding relationship.

[0051] Specifically, the control object of the PLC program is mapped one by one with the mechanism in the simulation environment through the variable address table, so that the program drives the three-dimensional model to move.

[0052] In some specific embodiments, the simulation software also includes a beat statistics unit, including beat interval designation and beat statistics display. The beat interval designation is used to select the IO signal and state of the beat start point and the IO signal and state of the beat end point to be monitored; the beat statistics display is used to periodically record the data selected by the beat interval designation and perform statistics display according to the specified data start time and state.

[0053] Specifically, the beat statistics unit monitors and records the state changes of the IO signals, and then calculates the time interval between the state changes, that is, the beat, and performs continuous beat statistics on all monitored signals; during this period, the beat statistics unit selects the IO signal and state at the start of the beat to be monitored, as well as the IO signal and state at the end of the beat through the beat interval specification, for preparation before beat statistics. During the beat statistics process, the beat statistics display in the beat statistics unit records the data selected by the beat interval periodically, and displays statistics based on the specified data start time and state. Users can clearly understand the operating cycle of each input and output signal in the PLC program, which helps to improve the performance and stability of the overall system.

[0054] In some specific embodiments, the simulation software further includes a collision statistics unit, which includes a collision statistics display and a collision fault feedback.

[0055] The collision statistics display is used to count and display the collision point information generated when the model joint moves according to the received axis position information. The collision fault feedback is used to feedback the collision fault information generated when the model joint moves according to the received axis position information to the protocol analysis device.

[0056] Specifically, the collision statistics unit of the simulation software is responsible for counting and feeding back the collision situations generated by the model joints during the movement according to the received axis position information. Among them, the collision statistics display function will record and display the collision point information in real time, helping users to intuitively understand the collision situation of the model during movement. The collision fault feedback function will promptly feed back the relevant information to the protocol parsing device when a collision fault is detected, so that the PLC control program can stop the joint axis from moving after receiving the feedback, ensuring the accuracy and safety of the simulation process, and can help users promptly discover and solve the collision problems of the motion joints during the operation of the PLC program, avoiding potential equipment damage and program abnormalities. Through detailed collision statistics and analysis, users can optimize equipment design and program logic, reduce the possibility of collisions, and improve the safety and reliability of the system.

[0057] This application also includes: an IO trigger logic configuration page.

[0058] The IO trigger logic configuration page is used to configure the input signal of the PLC. The input signal can configure the position information of the associated motion joint and the status information of the IO signal to set the status value. When the PLC program is running, the status value can be automatically calculated and assigned according to the configured information, thereby realizing the automatic operation of the PLC program.

[0059] The IO trigger logic configuration page provides users with flexible configuration options. They can adjust the binding relationship between PLC variables and model joints and the trigger conditions of input signals according to actual needs to achieve precise control of the simulation process.

[0060] This application uses a protocol parsing device + simulation software to set the industrial bus protocol currently used to connect to the PLC. It can connect to PLCs of various mainstream brands and realize the configurability of IO signal trigger logic, solving the two major problems of PLC brand compatibility and IO simulation. It truly puts the debugging work in advance, and the debugged program can be directly used in actual equipment, thereby achieving the purpose of shortening the construction period.

[0061] Secondly, through virtual debugging, mechanical, electrical, and process functions can be coordinated and work can be carried out in parallel. In this way, mechanical engineers can discover problems in advance and reduce changes. Electrical engineers can test program completeness and shorten the debugging cycle. Process engineers can discover process problems in advance and reduce delivery risks.

[0062] In some specific embodiments, selecting 3D software for model design and export includes:

[0063] Set the motion joint parameters in SolidWorks software, including joint tree structure, joint name, motion mode, motion vector and motion range.

[0064] Use the URDF plug-in to export the designed model in URDF data format.

[0065] Specifically, first, open the model file that needs to set the motion joint parameters in SolidWorks software. In the kinematic device of SolidWorks, build a tree structure of joints according to the actual situation of the model, and then assign a unique name to each joint. According to the motion requirements of the model, the user needs to define the motion mode (such as rotation, translation, etc.) and motion vector (i.e., the direction and size of the motion) for each joint, and set the motion range for each joint. Use the URDF plug-in to open the model to be exported in SolidWorks, and ensure that the model meets the requirements of the URDF format. During the URDF export process, set the relevant parameters, generate and export the file in the URDF data format.

[0066] The file contains information such as the model's joint tree structure, joint names, movement modes, movement vectors, and movement range, as well as the model's physical properties such as geometry, mass, and inertia.

[0067] By performing intuitive model design and kinematic simulation in SolidWorks, and then exporting the model in URDF format, simulation and control can be performed directly in the virtual environment, avoiding the tedious model conversion and debugging work in the traditional development process; by accurately setting the motion joint parameters in SolidWorks and exporting the model in URDF data format, users can ensure that the simulation of the robot in the virtual environment has higher accuracy and reliability.

[0068] Specifically, start the simulation software and ensure that it is in a state where it can receive model loading. In the simulation software, load and run the model import unit. Through the model import unit, import the URDF model previously exported from the design software. After importing the URDF model, the simulation software will automatically identify and display the various motion joints in the model. At the same time, the software will also read and display the parameters of these joints, such as name, type, position, etc., and then read the joint parameters of the URDF model from the simulation software. At the same time, parse the variables in the PLC program design, determine which variables are related to the movement of the model joints, and configure the relationship between the joint movement and the PLC variables. In the simulation software, load and run the protocol parsing device, receive information from the protocol parsing device through the data receiving unit, decompose and organize the information, and need to return the corresponding information to the protocol parsing device through the data sending unit. Finally, according to the state of the PLC variables, the model control device will drive the joints in the URDF model to perform position / angle transformation.

[0069] like Figure 3 As shown, a specific implementation of the present application is to take the test object as an example of a testing device. The feed lifting clamp moves horizontally on the guide rail, clamps the test object on the feed conveyor belt, and puts it into the testing station 1 or the testing station 2. The testing station 1 or the testing station 2 moves longitudinally in the respective testing guide rails, moves the test object to the testing equipment for testing, and moves it out after the test is completed. The discharging manipulator grabs the test object after the test by moving horizontally on the guide rail. If the test is qualified, it is put into the discharging conveyor belt 1, and if the test is unqualified, it is put into the discharging conveyor belt 2.

[0070] The specific implementation steps are as follows: select a protocol analysis device that supports EtherCat and EtherNet interfaces, use Winform programming language to write the UI interface in the simulation software device, and use Unity 3D engine to write the 3D part of the simulation software device; install the simulation software on the PC; select Omron PLC (NJ501-1400) equipment, and write the PLC program according to the design requirements of the detection equipment; link the PLC equipment, protocol analysis device and PC computer through the network; set the virtual slave memory address corresponding to the variable in the PLC program on the PLC programming software; compile the PLC program and send it to the equipment for operation; set the motion joint parameters in the SolidWorks software including: joint tree structure, joint name, motion mode, motion vector, motion range, etc. Use the URDF plug-in to export the design model in the URDF data format; run the model import unit in the simulation software, load the URDF model, display and set the parameters of each motion joint; configure the relationship between joint motion and PLC variables in the simulation software based on the URDF model joint parameters exported by the detection equipment and the variables in the PLC program design; run the model data receiving unit in the simulation software, receive the information from the protocol parsing device, decompose, organize and return the information, and drive the model joints to perform position / angle transformation.

[0071] The above describes the specific embodiments of the present application. It should be understood that the present application is not limited to the above specific embodiments, and those skilled in the art can make various modifications or variations within the scope of the claims, which does not affect the substantive content of the present application. The above preferred features can be used in any combination without conflicting with each other.

Claims

1. A virtual simulation platform, characterized in that: include: Protocol parsing device and simulation software; The protocol analysis device is connected to the PLC and the simulation software, receives the first data information sent from the PLC through the industrial bus, converts the first data information into a format that meets the input requirements of the simulation software, obtains the second data information and sends it to the simulation software; The first data information and the second data information are data information required for simulating a simulation object; The simulation software receives the second data information sent by the protocol parsing device, and drives the 3D model to move and display according to the second data information. At the same time, the simulation software performs virtual simulation according to the simulation object and the second data information, generates the third data information of the simulation object at the application level, and sends it to the protocol parsing device. After processing, the protocol parsing device sends it to the PLC.

2. A virtual simulation platform according to claim 1, characterized in that: The first data information and the second data information include: The first data information and the second data information both include one or more of the position, speed, acceleration, and IO signal data of each axis; The third data information includes one or more of IO data, position feedback data, and alarm information data.

3. A virtual simulation platform according to claim 2, characterized in that: The protocol parsing device comprises: The protocol setting unit is used to set the industrial bus protocol currently used to connect to the PLC; The data processing unit is used to receive the first data information sent by the PLC through the set industrial bus protocol, and send it to the simulation software after processing, so as to drive the action of the three-dimensional model in the simulation software and perform virtual simulation; at the same time, it also receives the third data information sent from the simulation software, and sends it to the PLC after processing.

4. A virtual simulation platform according to claim 2, characterized in that: The simulation software includes: Model import unit, used to import 3D models in common formats and configure model parameters; A data mapping unit, used for mapping the address of the data sent by the protocol analysis device with the three-dimensional model; A data receiving unit, configured to receive the second data information sent by the protocol parsing device; A 3D visualization unit, used to drive the 3D model action and display according to the received second data information; IO setting unit, used for configuration and automatic operation of IO signal trigger logic; The data sending unit sends the third data information to the protocol analysis device according to the set logic and motion state.

5. A virtual simulation platform according to claim 1, characterized in that: The simulation software also includes a beat statistics unit, which includes beat interval designation and beat statistics display; The beat interval designation is used to select the IO signal and state at the beat start point and the IO signal and state at the beat end point to be monitored; The beat statistics display is used to periodically record the data selected by the beat interval and perform statistics display according to the specified data start time and status.

6. A virtual simulation platform according to claim 1, characterized in that: The simulation software also includes a collision statistics unit, which includes collision statistics display and collision fault feedback; The collision statistics display is used to count and display the collision point information generated when the model joint moves according to the received axis position information; The collision fault feedback is used to feed back the collision fault information generated when the model joint moves according to the received axis position information to the protocol analysis device.

7. A virtual simulation platform according to claim 4, characterized in that: The IO setting unit is used to perform automatic triggering settings of IO, specify the state of the IO signal to be set, select the triggering conditions, including IO data, servo position data and time delay data, and set the conditions by logical combination of AND, OR and NOT to ensure that the IO signal is automatically triggered according to the set conditions.

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