Simulation system

Abstract

The invention provides a simulation system capable of debugging control software without operating an actual device even if the control specification of the actual device is unknown. A simulation system is provided with a temporary simulation model (M2), a control command value output unit (10), and a virtual controller unit (60). The temporary simulation model (M2) simulates the operation of the actual device (100) by a temporary specification different from the control specification of the actual device (100). A control command value output unit (10) outputs a control command value (V) in accordance with control software (S). The virtual controller unit (60) operates the temporary simulation model (M2) in accordance with the control command value (V). According to this configuration, even if the actual control specification is unknown, it is possible to evaluate whether or not the control command value (V) output from the control software (S) is appropriate using the temporary simulation model (M2). As a result, it is possible to debug the control software (S) without operating the actual device (100).

Description

Technical Field

[0001] The present invention relates to a simulation system for simulating the operation of an actual device on a computer. Background Art

[0002] Conventional simulation systems such as HILS (Hardware In The Loop Simulation) and SILS (Software In The Loop Simulation) are known. These systems simulate the operation of actual devices based on control software on a computer. Using these simulation systems allows debugging of control software without actually operating the device.

[0003] A conventional simulation system is described in Patent Document 1, for example.

[0004] However, existing simulation systems assume that the control specifications of the actual device are known. Conventional methods cannot generate simulation models without knowing the control specifications of the actual device. In such cases, the actual device must be operated in order to debug the control software.

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2009-295126 Summary of the Invention

[0006] Therefore, an object of the present invention is to provide a simulation system that can debug control software without operating the actual device even when the control specifications of the actual device are unknown.

[0007] Means for solving problems

[0008] In order to solve the above-mentioned problems, the first invention of the present application is a simulation system using a computer, which comprises: a temporary simulation model, which simulates the operation of the actual device on a computer through temporary specifications different from the control specifications of the actual device; a control instruction value output unit, which outputs the control instruction value used in the control of the actual device according to the control software installed in the computer; a memory, which stores the control instruction value; and a virtual controller unit, which causes the temporary simulation model to operate according to the control instruction value read from the memory.

[0009] A second invention of the present application is the simulation system of the first invention, further comprising an actual controller portion configured to control the actual device in accordance with the control instruction value read from the memory.

[0010] The third invention of the present application is a simulation system of the first invention or the second invention, wherein the actual device includes a first unit with known control specifications and a second unit with unknown control specifications, and the simulation system has a simulator, the simulator having: a first simulation model, which simulates the action of the first unit on a computer through the control specifications of the first unit; and a second simulation model, which is a temporary simulation model that simulates the action of the second unit on a computer through temporary specifications different from the control specifications of the second unit, and the virtual controller unit causes the first simulation model and the second simulation model to operate according to the control instruction value read from the memory.

[0011] A fourth invention of the present application is the simulation system according to any one of the first to third inventions, further comprising a display unit that displays a simulation result of the provisional simulation model.

[0012] A fifth invention of the present application is the simulation system according to any one of the first to fourth inventions, further comprising a parameter correction unit that corrects parameters set in the control software.

[0013] According to the first to fifth inventions of this application, even when the control specifications of the actual device are unknown, the adequacy of the control command values ​​output by the control software can be evaluated based on the temporary simulation model. This allows debugging of the control software without operating the actual device.

[0014] In particular, according to the second invention of this application, the actual device and the temporary simulation model are operated according to the control command values ​​stored in a common memory. This enables simulation based on the temporary simulation model to be performed with high accuracy.

[0015] In particular, according to the third invention of this application, for a first unit whose control specifications are known, the control software can be debugged using a first simulation model generated based on the actual specifications. Furthermore, for a second unit whose control specifications are unknown, the control software can be debugged using a second simulation model generated based on the provisional specifications.

[0016] In particular, according to the fourth invention of the present application, it is possible to visually confirm whether the simulation result of the temporary simulation model is appropriate.

[0017] In particular, according to the fifth invention of the present application, when it is determined that the simulation result of the temporary simulation model is inappropriate, the parameters set in the control software can be corrected. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a block diagram showing the structure of the simulation system.

[0019] Figure 2 This is a flowchart showing the debugging sequence. DETAILED DESCRIPTION

[0020] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0021] <1.Simulation system structure>

[0022] Figure 1 This is a block diagram showing the structure of a simulation system 1 according to one embodiment of the present invention. This simulation system 1 simulates the operation of an actual device 100 on a computer 2 in order to debug control software S used to control the actual device 100. The actual device 100 is, for example, industrial machinery such as semiconductor manufacturing equipment, display manufacturing equipment, film forming equipment, and digital printers. However, the actual device 100 may also be a device other than those listed above.

[0023] like Figure 1 As shown, the simulation system 1 includes a control command value output unit 10 , a parameter correction unit 20 , a memory 30 , an actual controller unit 40 , a simulator 50 , a virtual controller unit 60 , and a display unit 70 .

[0024] The control command value output unit 10 is a processing unit that outputs a control command value V in accordance with the control software S installed in the computer 2. The control command value V is a command value used to control the actual device 100. For example, when the controlled part of the actual device 100 is a robot, the control command value V is a value indicating the coordinates of the start and end points of the robot's movement, the robot's rotation angle, and the like.

[0025] A plurality of parameters P are set in the control software S. The control software S outputs a control command value V according to the parameter P. Therefore, when an inappropriate parameter P is set in the control software S, the control command value V output from the control software S also becomes an inappropriate value.

[0026] The parameter correction unit 20 is a processing unit that corrects the parameters P set in the control software S. The parameter correction unit 20 corrects the parameters P of the control software S according to the values ​​input to the computer 2 by the user through the operation unit 80 such as a keyboard and a mouse.

[0027] The memory 30 is a storage medium that stores the control command value V. The control command value V outputted from the control command value output unit 10 is written into the memory 30. Furthermore, the memory 30 is communicatively connected to the actual controller unit 40 and the virtual controller unit 60. The actual controller unit 40 and the virtual controller unit 60 can read the control command value V stored in the memory 30.

[0028] The actual controller 40 is a controller that controls the operation of the actual device 100. The actual controller 40 is, for example, a PLC (Programmable Logic Controller). The actual controller 40 reads a control command value V from the memory 30 and controls the operation of the actual device 100 according to the control command value V.

[0029] The simulator 50 is a processing unit that simulates the operation of the actual device 100 on the computer 2. Figure 1 As shown, in this embodiment, the actual device 100 includes a first unit U1 and a second unit U2. Accordingly, the simulator 50 includes a first simulation model M1 that simulates the operation of the first unit U1 and a second simulation model M2 that simulates the operation of the second unit U2. Each simulation model M1 is generated by simulation software installed on the computer 2.

[0030] Regarding the first unit U1, the control specifications of the actual controller 40 are known. In this case, the first simulation model M1 is generated based on the known control specifications of the actual controller 40. The control specifications refer to, for example, the specifications of the interface between the actual controller 40 and the first unit U1.

[0031] On the other hand, regarding the second unit U2, it is assumed that the control specifications of the actual controller unit 40 are unknown. In this case, the second simulation model M2 is generated based on temporary specifications that differ from the control specifications of the actual controller unit 40 (hereinafter referred to as "actual specifications"). The second simulation model M2 is an example of a "temporary simulation model" in the present invention. Because the actual specifications are unknown, the user of the simulation system 1 determines temporary specifications that can reproduce the operation of the second unit U2 based on the control command value V, thereby generating the second simulation model M2.

[0032] The virtual controller unit 60 is a controller that operates the simulator 50. The virtual controller unit 60 is implemented by the CPU of the computer 2 operating according to a program installed in the computer 2. The virtual controller unit 60 reads a control command value V from the memory 30 and operates the first simulation model M1 and the second simulation model M2 according to the control command value V.

[0033] The display unit 70 is a device that displays the simulation results of the simulator 50. A liquid crystal display is used, for example, for the display unit 70. The display unit 70 is electrically connected to the computer 2. The simulator 50 displays the simulation results of the first simulation model M1 and the simulation results of the second simulation model M2 on the display unit 70. Specifically, the simulator 50 causes the target part of the three-dimensional model corresponding to the actual device 100 to operate based on the simulation results. The display unit 70 displays the operation of the three-dimensional model on the screen.

[0034] <2. Debugging of control software>

[0035] Next, debugging of the control software S using the above-described simulation system 1 will be described. Figure 2 This is a flowchart showing the debugging sequence.

[0036] like Figure 2 As shown, when debugging the control software S, the control command value output unit 10 first outputs a control command value V according to the control software S for which a certain parameter P is set (step S1). Here, the control command value V includes a control command value V for the first unit U1 and a control command value V for the second unit U2. The control command value V outputted from the control command value output unit 10 is stored in the memory 30.

[0037] Next, the virtual controller 60 reads the control command value V from the memory 30. The virtual controller 60 then operates the simulator 50 based on the control command value V (step S2). Specifically, the virtual controller 60 operates the first simulation model M1 based on the control command value V for the first unit U1. Furthermore, the virtual controller 60 operates the second simulation model M2 based on the control command value V for the second unit U2.

[0038] The simulator 50 displays the simulation results of the first simulation model M1 and the simulation results of the second simulation model M2 on the display unit 70 (step S3 ).

[0039] The user visually checks the simulation results displayed on the display unit 70. The user then determines whether the simulation results for the first simulation model M1 and the simulation results for the second simulation model M2 are appropriate (step S4). For example, if the robot interferes with other components while moving in the three-dimensional model displayed on the display unit 70, or if the robot's stopped position is not the correct one, the user determines that the simulation results are inappropriate.

[0040] If the simulation results are inappropriate (step S4: No), the user corrects the parameters P of the control software S (step S5). For example, if the simulation results of the first simulation model M1 are inappropriate, the user corrects the parameters P associated with the first unit U1 of the control software S. Alternatively, if the simulation results of the second simulation model M2 are inappropriate, the user corrects the parameters P associated with the second unit U2 of the control software S.

[0041] Specifically, the user operates the operating unit 80 to input a correction value for the parameter P of the control software S. Here, the user inputs a parameter P that is increased or decreased from the existing parameter P based on the simulation results. Then, the parameter correction unit 20 of the computer 2 corrects the parameter P of the control software S to the input value.

[0042] After correcting the parameters P of the control software S, the process returns to step S1 and repeats steps S1 through S4. Steps S1 through S5 are then repeated until the simulation results are determined to be appropriate in step S4. Finally, if the user determines in step S4 that the simulation results are appropriate (step S4: Yes), debugging of the control software S ends.

[0043] As described above, in the simulation system 1 , simulation models M1 and M2 corresponding to the units U1 and U2 of the actual device 100 are generated, and the control software S is debugged based on the simulation results of the simulation models M1 and M2 .

[0044] In particular, in this simulation system 1, when the control specifications are unknown, as in the case of the second unit U2, a temporary simulation model is generated using temporary specifications that differ from the actual specifications, and simulation results are output. Conventionally, simulation results were unavailable for units with unknown control specifications. Furthermore, when evaluating the control of units with unknown control specifications, only the output of certain control command values ​​V from the control software S was confirmed. In contrast, in the simulation system 1 of this embodiment, the appropriateness of the control command values ​​V written by the control software S to the memory 30 can be evaluated for the second unit U2 with unknown control specifications.

[0045] Therefore, by using the simulation system 1, even when the control specifications are unknown, the control software S can be debugged before manufacturing the actual device 100. Therefore, the parameters P of the control software S can be optimized before manufacturing the actual device 100.

[0046] <3. Modifications>

[0047] An embodiment of the present invention has been described above, but the present invention is not limited to the above embodiment.

[0048] In the above embodiment, the actual device 100 includes two units U1 and U2. However, the number of units included in the actual device 100 may be one, or three or more.

[0049] In the above embodiment, the simulation results output from the simulator 50 are based on the three-dimensional model. However, the simulation results output from the simulator 50 may be information such as a two-dimensional model or numerical values.

[0050] In the above embodiment, a human user visually determines whether the simulation results displayed on the display unit 70 are appropriate. However, if the simulation results are inappropriate, the simulator 50 may automatically output an alarm. For example, if the robot interferes with other components in the simulation model, the simulator 50 may display a warning message on the display unit 70 or output a warning sound.

[0051] In the above embodiment, the control command value output unit 10, the memory 30, and the virtual controller unit 60 are provided in one computer 2. However, some of them may be provided in another computer connected via a network.

[0052] Furthermore, part of the elements in the above-described embodiments and modifications may be omitted, or other elements may be added without departing from the spirit of the present invention.

[0053] Description of Reference Signs

[0054] 1: Simulation system

[0055] 2: Computer

[0056] 10: Control command value output unit

[0057] 20: Parameter correction department

[0058] 30: Memory

[0059] 40: Actual controller part

[0060] 50: Simulator

[0061] 60: Virtual controller unit

[0062] 70: Display unit

[0063] 80: Operation Department

[0064] 100: Actual device

[0065] M1: First simulation model

[0066] M2: Second simulation model

[0067] P: parameter

[0068] S: Control software

[0069] U1: Unit 1

[0070] U2: Unit 2

[0071] V: Control command value.

Claims

1. A simulation system using a computer, characterized in that: have: a temporary simulation model that simulates the operation of the actual device on a computer using temporary specifications that differ from the control specifications of the actual device; a control command value output unit that outputs a control command value used in controlling the actual device in accordance with control software installed in the computer; a memory storing the control instruction value; as well as A virtual controller section operates the temporary simulation model according to the control command value read from the memory.

2. The simulation system according to claim 1, wherein: The simulation system further includes an actual controller unit configured to control the actual device according to the control command value read from the memory.

3. The simulation system according to claim 1 or 2, characterized in that The actual device includes a first unit with known control specifications and a second unit with unknown control specifications. The simulation system includes a simulator, The simulator has: a first simulation model that simulates the operation of the first unit on a computer using the control specifications of the first unit; and a second simulation model, which is the temporary simulation model for simulating the operation of the second unit on a computer using temporary specifications different from the control specifications of the second unit; The virtual controller operates the first simulation model and the second simulation model according to the control command value read from the memory.

4. The simulation system according to claim 1 or 2, characterized in that: The simulation system further includes a display unit that displays a simulation result of the temporary simulation model.

5. The simulation system according to claim 1 or 2, characterized in that: The simulation system further includes a parameter correction unit that corrects parameters set in the control software.

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