Integrated industrial simulation control system and device

Abstract

The invention relates to the technical field of industrial simulation control, in particular to an integrated industrial simulation control system and equipment, which are used for carrying out simulation control of sorting and transmission tasks, and the system comprises an operation module which is used for carrying out sorting and transmission tasks and obtaining monitoring data in the sorting and transmission task process; the data analysis and processing module is used for analyzing the tension change condition of the integrated industrial simulation control system according to the monitoring data to obtain an adjustment requirement; sending a control instruction based on the adjustment demand, and analyzing the response time of the control instruction to obtain the response hysteresis of the control instruction; the data adjustment module is used for comprehensively adjusting the response hysteresis of the demand and the control instruction to obtain a parameter optimization coefficient of the integrated industrial simulation control system, feeding back the parameter optimization coefficient to the operation module, and dynamically adjusting the tension in sorting and transmission tasks through the operation module; and the load change on the conveyor belt is responded in time, and the efficient and stable industrial control target is achieved.

Description

Technical Field

[0001] This invention relates to the field of industrial simulation control technology, specifically to an integrated industrial simulation control system and equipment. Background Technology

[0002] In modern industrial education and vocational training, the application of integrated industrial simulation control systems and equipment is receiving increasing attention, especially in experiments involving conveyor belt sorting and pulley transmission. The purpose of these experiments is to cultivate students' and trainees' in-depth understanding and practical skills in automation control, logistics management, and production processes. Through industrial simulation control systems, a real working environment can be simulated, enabling students to learn and master relevant technologies under safe and controllable conditions, significantly improving teaching effectiveness.

[0003] Existing integrated industrial simulation control systems and equipment generally include the following core modules: data acquisition module, simulation model module, control decision module, human-machine interface, and feedback and optimization module. While existing integrated industrial simulation control systems have played a positive role in teaching, they still have some shortcomings. For example, existing simulation models in laboratory environments may be affected by external interference factors, and when faced with rapidly changing experimental conditions, existing control systems may not be able to respond in a timely manner, causing operators to be unable to make timely adjustments, affecting the accuracy and feasibility of the experiment, and thus reducing the real-time performance of the control system. Furthermore, most existing control systems rely on fixed control strategies and lack intelligent adaptive capabilities, failing to adjust control parameters according to actual conditions, resulting in poor performance in complex tasks. Therefore, these limitations restrict the flexibility and efficiency of control systems in practical applications, affecting the cultivation of students' and trainees' ability to operate complex industrial systems. Summary of the Invention

[0004] To address the technical problems of poor real-time performance in existing integrated industrial simulation control systems, which prevent operators from making timely adjustments, and poor adaptive capabilities, resulting in unsatisfactory response to complex tasks and affecting the flexibility and efficiency of the control system in practical applications, this invention aims to provide an integrated industrial simulation control system for simulation control of sorting and transmission tasks. The specific technical solution adopted is as follows: The operation module is used to: perform sorting and transfer tasks, and acquire monitoring data during the sorting and transfer process; The data analysis and processing module is used to: analyze the tension changes of the integrated industrial simulation control system based on monitoring data to obtain adjustment requirements; issue control commands based on adjustment requirements; analyze the response time of the control commands to obtain the response hysteresis of the control commands; The data adjustment module is used to comprehensively adjust the response lag of demand and control commands, obtain the parameter optimization coefficients of the integrated industrial simulation control system, and feed them back to the operation module, so as to dynamically adjust the tension in sorting and transmission tasks through the operation module.

[0005] Preferably, the operation module includes a control unit and a conveyor belt, sensors, and sorting equipment electrically connected to the control unit. The sensors are installed on the conveyor belt and collect monitoring data from the conveyor belt, which is then uploaded to the control unit. Sorting points are determined based on the conveyor belt. The sorting equipment is positioned close to the sorting points and records the success rate of sorting items and the item transit time, which is then uploaded to the control unit. The control unit controls the operation of the conveyor belt based on the monitoring data, the success rate of sorting items, and the item transit time.

[0006] Preferably, the monitoring data includes tension monitoring data, current monitoring data, and weight monitoring data.

[0007] Preferably, the adjustment requirements are obtained by analyzing the tension changes of the integrated industrial simulation control system based on monitoring data, including: The expected tension range is preset and compared with tension monitoring data to determine the tension changes of the conveyor belt. Combined with current monitoring data, the possibility of improper conveyor belt tension setting is obtained. Based on the success rate of sorting items and the time it takes for items to pass through, the efficiency of the sorting equipment in sorting items is judged, and the adjustment requirements are determined.

[0008] Preferably, a preset tension expectation range is established and compared with tension monitoring data to determine the tension variation of the conveyor belt. Combined with current monitoring data, the possibility of improper conveyor belt tension setting is determined, including: The complexity of the conveyor belt tension variation is determined by the expected tension range and tension monitoring data, and a judgment threshold is set. If the complexity of the conveyor belt tension variation is greater than the judgment threshold, it indicates that there is an inappropriate change in the tension of the conveyor belt. The current expectation range is preset. If the current monitoring data at the current monitoring time is within the current expectation range, and the current monitoring data at the next adjacent monitoring time is outside the current expectation range, it indicates a sudden change in current. When there are inappropriate changes in the tension of the conveyor belt and a sudden change in the current, the possibility of improper conveyor belt tension setting is quantified by combining the current monitoring data at the corresponding two monitoring times with the complexity of the conveyor belt tension change.

[0009] Preferably, the efficiency of the sorting equipment in sorting items is determined based on the success rate of sorting items and the time it takes for items to pass through, and the adjustment requirements are determined accordingly, specifically as follows: The efficiency of the sorting equipment is determined based on the success rate of sorting items and the time it takes for items to pass through. A screening threshold is set. When the efficiency of the sorting equipment is less than the screening threshold, the efficiency of the sorting equipment is combined with the possibility of improper conveyor belt tension settings to determine the adjustment requirements for the conveyor belt tension.

[0010] Preferably, control commands are issued based on adjustment requirements, and the response time of the control commands is analyzed to obtain the response hysteresis of the control commands, including: Based on the adjustment requirements, control commands are issued, and the time difference between issuing the control command and the conveyor belt receiving the control command is recorded. Based on weight monitoring data and tension monitoring data, the corresponding weight changes and tension changes are determined, and the response lag of control commands is determined by combining the time difference.

[0011] Preferably, the corresponding weight changes and tension changes are determined based on the weight monitoring data and tension monitoring data, specifically as follows: Based on the weight monitoring data and tension monitoring data, corresponding weight monitoring curves and tension monitoring curves are obtained. The slope is determined by the monitoring data at any two adjacent monitoring time points in the curves, and the slope is analyzed to assess the synchronicity between weight changes and tension changes.

[0012] Preferably, by comprehensively adjusting the response lag of demand and control commands, the parameter optimization coefficients of the integrated industrial simulation control system are obtained and fed back to the operation module. The operation module dynamically adjusts the tension in the sorting and transmission tasks, including: By comprehensively adjusting the response lag of demand and control commands, the parameter optimization coefficients of the integrated industrial simulation control system are obtained. By combining the parameter optimization coefficients of the integrated industrial simulation control system with the original proportional gain value of the control unit, the adjusted proportional gain value is obtained and fed back to the control unit. Different scenarios are constructed for simulation testing to dynamically adjust the tension of the conveyor belt.

[0013] To address the aforementioned issues, this application also provides an integrated industrial simulation control device, comprising a processor, a communication interface, a memory, and a communication bus, wherein the processor, communication interface, and memory communicate with each other via the communication bus, and the processor calls logical instructions from the memory to execute the integrated industrial simulation control system described in any of the preceding claims.

[0014] The present invention has the following beneficial effects: 1. An integrated industrial simulation control system is formed by integrating the operation module, data analysis and processing module, and data adjustment module. Based on monitoring data, the tension changes of the conveyor belt are determined, identifying the possibility of improper conveyor belt tension settings. Then, based on the efficiency of the operation module in processing items, combined with the possibility of improper conveyor belt tension settings, the adjustment requirements of the integrated industrial simulation control system are analyzed. Next, the response time of control commands is analyzed to obtain response lag. Finally, the parameter optimization coefficients in the integrated industrial simulation control system are obtained. The tension of the conveyor belt is dynamically adjusted through the control unit to ensure that the integrated industrial simulation control system can respond promptly to load changes on the conveyor belt. Through continuous feedback and optimization, the system adapts to constantly changing production demands, achieving efficient and stable industrial control objectives.

[0015] 2. The integrated industrial simulation control device provided by this invention has the same beneficial effects as the integrated industrial simulation control system provided by this invention, and will not be described in detail here. Attached Figure Description

[0016] To more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic block diagram of an integrated industrial simulation control system provided in one embodiment of the present invention; Figure 2 A schematic diagram of tension monitoring data provided in an integrated industrial simulation control system according to an embodiment of the present invention; Figure 3 A schematic diagram of current monitoring data for an integrated industrial simulation control system provided in one embodiment of the present invention; Figure 4 This is a schematic diagram of weight monitoring data for an integrated industrial simulation control system provided in one embodiment of the present invention. Detailed Implementation

[0018] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of an integrated industrial simulation control system and device proposed according to the present invention. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0020] The specific solution of an integrated industrial simulation control system and equipment provided by the present invention will be described in detail below with reference to the accompanying drawings.

[0021] Existing simulation models and control systems may fail to respond promptly to rapidly changing experimental conditions, hindering operators from making timely adjustments and impacting the accuracy and reliability of the experiment. This results in poor real-time performance of the control system. Furthermore, most existing systems rely on fixed control strategies and lack intelligent adaptive capabilities. Therefore, an integrated industrial simulation control system is formed by integrating operation, data monitoring, data analysis and processing, and data adjustment modules. By analyzing tension, current, and weight monitoring data, parameter optimization coefficients are obtained for the integrated industrial simulation control system. The entire system is then dynamically adjusted to ensure timely response to load changes on the conveyor belt. Through continuous feedback and optimization, the system adapts to constantly changing production demands, achieving efficient and stable industrial control objectives.

[0022] Please see Figure 1 The diagram illustrates a schematic block diagram of an integrated industrial simulation control system provided in the first embodiment of the present invention, used for simulation control of sorting and transmission tasks. The system includes: The operation module is used to: perform sorting and transfer tasks, and acquire monitoring data during the sorting and transfer process; The data analysis and processing module is used to: analyze the tension changes of the integrated industrial simulation control system based on monitoring data to obtain adjustment requirements; issue control commands based on adjustment requirements; analyze the response time of the control commands to obtain the response hysteresis of the control commands; The data adjustment module is used to comprehensively adjust the response lag of demand and control commands, obtain the parameter optimization coefficients of the integrated industrial simulation control system, and feed them back to the operation module, so as to dynamically adjust the tension in sorting and transmission tasks through the operation module.

[0023] To better illustrate this, this embodiment simulates an industrial scenario for sorting and transport tasks to conduct actual teaching and training, cultivating students' and trainees' understanding and practical abilities in automation control, logistics management, and production processes. It can be noted that the laboratory is equipped with an operation module to complete sorting and transport tasks. Based on the operation module, data analysis and processing module, and data adjustment module, the laboratory is divided into multiple functional areas, including an experimental operation area, a control center, a data monitoring area, and a discussion and rest area. The setup of each area improves teaching efficiency and the learning experience of participants.

[0024] Furthermore, the operation module includes a control unit and a conveyor belt, sensors, and sorting equipment electrically connected to the control unit. The sensors are installed on the conveyor belt and collect monitoring data from the conveyor belt, which is then uploaded to the control unit. The sorting point is determined based on the conveyor belt. The sorting equipment is set close to the sorting point and records the success rate of sorting items and the item transit time, which is then uploaded to the control unit. The control unit controls the operation of the conveyor belt based on the monitoring data, the success rate of sorting items, and the item transit time.

[0025] Specifically, the conveyor belt is an adjustable speed conveyor belt to simulate a real industrial environment; sensors are used to monitor the presence and position of items on the conveyor belt to ensure the accuracy of the sorting task. That is, according to the actual application requirements, sensors are installed at each key position such as the input end of the conveyor belt, key turning points, and sorting points, and the sensors are correctly connected to the control unit; the control unit is used to read the monitoring data of the sensors to ensure real-time feedback of the monitoring data; the sorting equipment is used to automatically sort items on the conveyor belt; optionally, the integrated industrial simulation control system can adjust the robot's recognition and sorting algorithms through programming, and display the deviation between the rotation speed and control commands in real time through a visual interface, thereby optimizing and adjusting the control process.

[0026] To clarify, a sorting point refers to one or more specific locations pre-defined in a conveyor belt. It can be a fixed location on the conveyor belt or a specific area identified by sensors or sorting equipment. When items pass through a sorting point during transport on the conveyor belt, sorting equipment is used to remove the items from the conveyor belt or guide them to subsequent sorting channels.

[0027] Furthermore, the monitoring data includes tension monitoring data, current monitoring data, and weight monitoring data.

[0028] It is explained that after acquiring the monitoring data, the monitoring time period is divided to facilitate subsequent modules to perform accurate analysis of the monitoring data for each monitoring time period; preferably, in this embodiment, each monitoring time period is defined as 5 minutes.

[0029] As an optional implementation, sensors include, but are not limited to, strain gauges, temperature sensors, flow meters, pressure sensors, current sensors, and photoelectric sensors to obtain tension, current, and weight monitoring data for subsequent data support. Strain gauges are used to acquire tension monitoring data, monitoring the degree of deformation of the object under external force to calculate the magnitude of the tension borne by the object, i.e., measuring tension through strain changes. Pressure sensors are used to acquire weight monitoring data; current sensors are used to acquire current monitoring data; and temperature sensors, flow meters, and photoelectric sensors are used to assist in determining the presence, position, or velocity of the object. The control unit is a PLC (Programmable Logic Controller), PID (Proportional Integral Derivative) controller, or industrial computer, used to configure sampling frequency, data format, threshold settings, and other acquisition parameters to ensure that the output signal of each sensor can be correctly read to accurately and in real-time reflect the relevant data of the object.

[0030] Specifically, the control unit performs preprocessing on the received monitoring data, including format conversion, data filtering, and data correction. This converts the monitoring data from its original format to a format more suitable for subsequent processing, and removes any noise and interference to ensure data purity. Then, the control unit corrects the monitoring data to rectify deviations and errors, thereby improving the accuracy and reliability of the monitoring data. Through preprocessing, higher-quality monitoring data is provided to support subsequent module processing.

[0031] Preferably, the preprocessed monitoring data can be stored in a local database or a cloud database for effective preservation, facilitating subsequent querying, analysis, and historical record tracking, enabling faster retrieval and utilization for subsequent task requirements. Furthermore, the real-time monitoring data can be displayed in charts, numbers, or graphs through a human-computer interaction interface, making the monitoring data more intuitive and easy to understand. Analysis can then be performed to obtain the final analysis results, optimizing the control strategy, such as adjusting sensor sensitivity or relevant parameters of industrial equipment, to achieve more efficient operation of the integrated industrial simulation control system and improve the reliability of the entire simulation system.

[0032] Please see Figure 2This diagram illustrates tension monitoring data of an integrated industrial simulation control system provided in the first embodiment of the present invention. The horizontal axis represents monitoring time in seconds (s), and the vertical axis represents tension in Newtons (N). It is understandable that analyzing the tension changes of the conveyor belt can provide reliable data support for improving equipment operating efficiency and maintenance management capabilities. Appropriate tension ensures smooth operation of the conveyor belt, reduces slippage and slippage, and improves the efficiency and accuracy of transporting goods. Excessive or insufficient tension can lead to abnormal wear of the conveyor belt and its rollers, bearings, and other components, affecting the overall performance and service life of the conveyor belt. Timely monitoring and adjustment of tension can effectively extend the service life of the equipment, ensure its optimal operation, and thus improve production efficiency and economic benefits.

[0033] Furthermore, based on the analysis of monitoring data regarding tension changes in the integrated industrial simulation control system, adjustment requirements are derived, including: Step S11: Preset the expected tension range and compare it with the tension monitoring data to determine the tension change of the conveyor belt. Combined with the current monitoring data, determine the possibility of improper tension setting of the conveyor belt.

[0034] The explanation is as follows: Based on the preset tension expectation range of the current integrated industrial simulation control system, the upper tension limit and the lower tension limit are obtained according to this range, and are denoted accordingly. and , to serve as prior data for tension monitoring.

[0035] Further, step S11 includes: Step S111: Determine the complexity of the conveyor belt tension change by using the expected tension range and tension monitoring data, and set a judgment threshold. If the complexity of the conveyor belt tension change is greater than the judgment threshold, it indicates that there is an inappropriate change in the tension of the conveyor belt.

[0036] Optionally, in this embodiment, the judgment threshold is: It is precisely set according to the specific parameters of the actual industrial environment.

[0037] Specifically, the complexity of the conveyor belt tension variation, i.e., the fluctuation of tension variation, is determined by combining the tension monitoring data in any monitoring period with the expected tension range. The corresponding calculation formula is as follows: in, This indicates the complexity of changes in conveyor belt tension; This indicates the number of monitoring locations during the current monitoring period; This indicates that during the current monitoring period, the [number]th [time period]... Tension monitoring data at each monitoring point; Indicates the lower limit of tension; This indicates the upper limit of tension.

[0038] If the complexity of the conveyor belt tension variation exceeds the judgment threshold, that is... This indicates that the tension of the conveyor belt is not properly changing during the current monitoring period, meaning that the tension monitoring data fluctuates greatly or that the tension monitoring data exceeds the expected tension range at multiple consecutive adjacent monitoring times. When the tension monitoring data is below the lower tension limit, it indicates that the tension of the conveyor belt is too low. When the tension monitoring data is above the upper tension limit, it indicates that the tension of the conveyor belt is too high. This suggests that frequent shaking or vibration occurs during the operation of the conveyor belt, affecting its operating efficiency. This may be due to uneven distribution of items on the conveyor belt causing instantaneous tension changes, or malfunctions in the conveyor belt's drive system or tension adjustment device causing unstable tension control. Further analysis based on the tension fluctuations confirms that there is indeed a problem with the conveyor belt's tension settings.

[0039] Conversely, if the complexity of the conveyor belt tension variation is less than or equal to the judgment threshold, i.e. This indicates that the tension setting of the conveyor belt is normal during the current monitoring period, meaning that the fluctuation of the tension monitoring data during the current monitoring period is small or the tension monitoring data does not exceed the expected tension range.

[0040] Please see Figure 3 The diagram illustrates a current monitoring data of an integrated industrial simulation control system provided in the first embodiment of the present invention, wherein the horizontal axis represents the monitoring time in seconds (s), and the vertical axis represents the current in amperes (A).

[0041] Understandably, the possibility of improper conveyor belt tension setting refers to the quantitative data of situations where the tension setting in the conveyor belt is inaccurate or does not meet the predetermined requirements; and then potential problems with the tension setting can be identified by monitoring the changing trends of current and tension.

[0042] Step S112: Preset the expected current range. If the current monitoring data at the current monitoring time is within the expected current range, and the current monitoring data at the next adjacent monitoring time is outside the expected current range, it indicates a sudden change in current.

[0043] It can be explained that the upper and lower limits of the current are determined according to the preset expected current range. If the current monitoring data at the current monitoring time is within the expected current range, and the current monitoring data at the next adjacent monitoring time is greater than the upper current limit or less than the lower current limit, it indicates a sudden increase or decrease in current, respectively. If the current monitoring data during the current monitoring period is within the expected current range, it indicates that the current is normal, meaning that the improper tension change of the conveyor belt is unrelated to the current setting and is a non-current-related cause of excessively high or low tension. Therefore, it is necessary to analyze other reasons affecting the improper tension setting. Conversely, if the current suddenly increases or decreases, it indicates that the current change is more complex, causing changes in the tension of the conveyor belt. A sudden increase in current indicates an increase in the load or friction of the conveyor belt, while a sudden decrease indicates a decrease in the load or slippage of the conveyor belt. Combining the tension monitoring data with the current monitoring data can accurately reflect the changes caused by improper tension setting.

[0044] Step S113: When there is an improper change in the tension of the conveyor belt and a sudden change in the current, the possibility of improper setting of the conveyor belt tension is quantified by combining the current monitoring data at the corresponding two monitoring time positions with the complexity of the change in the conveyor belt tension.

[0045] Specifically, by combining the current monitoring data at the two monitoring points corresponding to the sudden change in current with the complexity of the conveyor belt tension changes, the possibility of improper conveyor belt tension settings is quantified for further analysis. The corresponding calculation formula is as follows: in, This indicates the possibility of improper conveyor belt tension settings; This indicates the complexity of changes in conveyor belt tension; This indicates the number of monitoring locations during the current monitoring period; , These represent the number of times the current monitoring period begins. The and the first Current monitoring data at each monitoring point.

[0046] The explanation is as follows: based on the specific simulation or actual industrial environment, preset thresholds are set if... If the value is greater than or equal to the threshold, it indicates a higher probability that the conveyor belt tension setting is improper during the current monitoring period, and a higher probability that there is a problem with the conveyor belt tension setting; in particular, when The value takes hour, The possibility of improper conveyor belt tension setting at this time is analyzed based on the current monitoring data at the last monitoring moment of the current monitoring period and the first monitoring moment of the next adjacent monitoring period. If the obtained... If the value is greater than or equal to the threshold, it indicates a problem with the tension setting at the connection point between the two monitoring time periods, requiring further analysis; if If the value is less than the threshold, it indicates that the data at the junction of the two monitoring time periods is highly consistent and the conveyor belt is operating normally, thus allowing for a more accurate assessment of the conveyor belt's operation. However, improper tension settings not only affect the stability of the conveyor belt and the safe transportation of goods, but may also affect the subsequent sorting process, thereby reducing the efficiency and reliability of the industrial control system. Therefore, an analysis of the sorting situation is conducted to determine whether improper tension settings are caused by the sorting situation.

[0047] Step S12: Determine the efficiency of the sorting equipment when sorting items based on the success rate of sorting items and the time it takes for items to pass through, and determine the adjustment requirements.

[0048] Understandably, tension settings directly affect the smoothness of conveyor belt operation and the movement of items on the conveyor belt. Based on the aforementioned possibility of improper tension settings, if the tension is improperly set, it may lead to unstable positions of items on the conveyor belt, increasing the risk of errors in the sorting process. For example, excessive tension may cause items to be over-compressed, resulting in changes in shape or damage to the items, affecting the identification and handling of the sorting equipment, reducing sorting efficiency, and increasing the probability of sorting errors. Insufficient tension may cause items to slide, tilt, or collide with each other on the conveyor belt, affecting the identification of item positions during the sorting process, making it impossible to accurately identify the position of items, and reducing sorting accuracy. Therefore, the tension monitoring data is analyzed to assist in the sorting of items in order to improve the stability of the overall system and thus improve the efficiency of industrial control objectives.

[0049] Furthermore, in step S12, specifically: The efficiency of the sorting equipment is determined based on the success rate of sorting items and the time it takes for items to pass through. A screening threshold is set. When the efficiency of the sorting equipment is less than the screening threshold, the efficiency of the sorting equipment is combined with the possibility of improper conveyor belt tension settings to determine the adjustment requirements for the conveyor belt tension.

[0050] Optionally, in this embodiment, the screening threshold is: It is precisely set according to the specific parameters of the actual industrial environment.

[0051] The success rate of sorting items is defined as the ratio of the number of successfully sorted items to the total number of items in each sorting task, denoted as [missing information]. And record the time it takes for the items to pass through the sorting point as .

[0052] Specifically, the efficiency of the sorting equipment in sorting items is determined by the following formula: in, This indicates the efficiency of the operation module when sorting items. This indicates the total number of records of the time an item passes through during the current monitoring period; Indicates the first The time recorded for passing through the sorting point; This indicates the success rate of all sorted items during the current monitoring period.

[0053] Understandably, the success rate of sorting items and the time taken to pass through the sorting point are not isolated phenomena; they influence each other and jointly determine the overall efficiency of the integrated industrial simulation control system in sorting tasks. The value of is used to prove that if the success rate of sorting items is high, but the time to pass through the sorting point is long, it means that although the items are sorted correctly, the processing speed is slow, indicating that the overall production efficiency needs to be improved. This leads to the determination of the adjustment requirements of the integrated industrial simulation control system to adjust the tension setting of the conveyor belt.

[0054] Make an explanation, when This indicates high efficiency in sorting items, meaning that items take a short time to pass through the sorting point and the sorting success rate is high. In other words, during the current monitoring period, the entire integrated industrial simulation control system can process items quickly and react rapidly, which in turn indicates that the conveyor belt tension setting is normal and the system is operating normally during the current monitoring period.

[0055] Conversely, if the sorting efficiency of the operation module is low, that is... This indicates that the items take a long time to pass through the sorting point and the sorting success rate is low, suggesting an improper change in the conveyor belt tension setting. Therefore, the tension needs to be adjusted accordingly. This involves combining the sorting equipment's efficiency with the possibility of an improper conveyor belt tension setting to determine the required tension adjustment. The goal is to ensure the sorting equipment's efficiency while adjusting the tension. The corresponding calculation formula is: in, This indicates an adjustment in demand; This indicates the possibility of improper conveyor belt tension settings; This indicates the efficiency of the operation module when processing items.

[0056] Understandably, assessing the success rate of sorting items based on the ratio of successfully sorted items to the total number of items in each sorting session can reflect that some items have a high error rate. This may be due to delays in the item identification process or insufficient responsiveness of the sorting equipment. Insufficient sorting accuracy not only affects customer satisfaction but may also lead to rework, inventory management problems, etc. Therefore, the concept of response time is proposed to ensure that the integrated industrial simulation control system can quickly adapt to changes and improve overall sorting efficiency.

[0057] Response time refers to the time required for the system to begin executing the corresponding task after receiving a control command requesting adjustments. In efficient industrial control environments, a fast response time is crucial for maintaining smooth production processes. Especially under dynamically changing production conditions, the system's responsiveness directly impacts sorting accuracy and overall processing efficiency.

[0058] Please see Figure 4 The diagram illustrates a weight monitoring data of an integrated industrial simulation control system provided in the first embodiment of the present invention, wherein the horizontal axis represents the monitoring time in seconds (s), and the vertical axis represents the weight in grams (g).

[0059] Furthermore, based on the adjustment requirements, control commands are issued, and the response time of these commands is analyzed to obtain the response lag of the control commands, including: Step S21: Issue control commands based on adjustment requirements, and record the time difference between issuing the control command and receiving the control command on the conveyor belt.

[0060] It is explained that the integrated industrial simulation control system may contain control commands requiring multiple adjustments. It is assumed that at least one adjustment requirement, i.e., a tension adjustment process, exists within each monitoring time period to achieve precise and real-time tension control, ensuring the smooth operation of the integrated industrial simulation control system in the industrial environment. The time difference between issuing the control command and receiving the control command on the conveyor belt is denoted as... .

[0061] Step S22: Based on the weight monitoring data and tension monitoring data, determine the corresponding weight change and tension change, and combine the time difference to determine the response lag of the control command.

[0062] Furthermore, in step S22, specifically: Based on the weight monitoring data and tension monitoring data, corresponding weight monitoring curves and tension monitoring curves are obtained. The slope is determined by the monitoring data at any two adjacent monitoring time points in the curves, and the slope is analyzed to assess the synchronicity between weight changes and tension changes.

[0063] It is explained that the weight monitoring curve and the tension monitoring curve are respectively denoted as... , And the slopes are all denoted as The curves are distinguished by subscripts and are used to reflect the rate of change in weight and tension, so as to infer the dynamic characteristics of the changes in weight and tension. Among them, the weight monitoring curve reflects the weight change of the items on the conveyor belt, and the tension monitoring curve reflects the tension change of the conveyor belt.

[0064] Understandably, changes in weight and tension on a conveyor belt need to be synchronized. An increase in the weight of the items requires the conveyor belt to overcome greater gravity. To ensure normal operation, the tension must increase accordingly to offset the increased weight, maintaining belt stability, preventing items from slipping or the belt from slipping, and ensuring smooth transport. Conversely, a decrease in item weight reduces the gravity the conveyor belt needs to overcome, resulting in less tension. This helps reduce energy consumption, lessens wear on the conveyor belt and related equipment, extends equipment lifespan, and avoids unnecessary tension, preventing damage or malfunction due to excessive tension. By adjusting tension appropriately based on weight changes, stable conveyor belt operation is effectively ensured, while reducing energy consumption and equipment wear, ensuring efficient and safe transport.

[0065] Furthermore, based on the synchronicity of the two changes, the response lag of the control command is determined by combining the time difference, and the control threshold is set according to the current industrial environment. The analysis yields the following calculation formula: in, Indicates the lag in the response of control commands; , These represent the values ​​of the weight monitoring curve and the tension monitoring curve, respectively, within the current monitoring period. The absolute value of the slope of the group; This represents the average value calculation; This represents the average time difference between the time the control command is issued and the time the conveyor belt receives the control command.

[0066] It can be explained that, This represents the average operation, i.e. It is used to synchronously assess tension and weight changes at multiple monitoring locations and to analyze preset values ​​based on the current industrial environment. A value less than the preset value indicates strong synchronization, meaning that within the current monitoring period, the weight change and tension change on the conveyor belt are synchronized, indicating that the current tension setting parameters are reasonable and applicable. The response lag of the control command is less than the control threshold. This indicates that the tension setting met expectations during the monitoring period, ensuring the stable operation of the integrated industrial simulation control system; conversely, A value greater than or equal to a preset value indicates a weaker synchronicity between tension changes and weight changes. This indicates that the response lag of control commands is high during the current monitoring period, and the tension needs to be adjusted accordingly based on the weight monitoring data.

[0067] Understandably, if the response time of tension to weight changes is too long, it indicates a problem with the conveyor belt, leading to inaccurate tension control and a lag phenomenon. This could cause items to slip or fall on the conveyor belt, affecting its normal operation and reducing the accuracy of item sorting. Analyzing the response time of control commands reveals the reaction speed of the integrated industrial simulation control system to tension changes. By comprehensively analyzing the relationship between weight changes and tension changes, the response lag of control commands is obtained to reflect changes in the load of the conveyor belt. This allows for dynamic adjustment of the conveyor belt tension, improving the flexibility of industrial equipment and enabling it to adapt to load changes in real time, maintaining the efficient and stable operation of the entire system.

[0068] It can be explained that the data adjustment module is used to improve the flexibility of the entire integrated industrial simulation control system. Flexibility refers to the ability of industrial equipment to quickly adapt and adjust when faced with different production needs, task changes and environmental changes. That is, by comprehensively analyzing the adjustment needs of tension and the response lag of issuing control commands, parameter optimization coefficients are introduced. With the help of control algorithms such as PID control, the control parameters can be automatically adjusted according to real-time monitored data, thereby improving the adaptability of the conveyor belt to different load changes.

[0069] Furthermore, by comprehensively adjusting the response lag of demand and control commands, the parameter optimization coefficients of the integrated industrial simulation control system are obtained and fed back to the operation module. The operation module then dynamically adjusts the tension in the sorting and transmission tasks, including: Step S31: By comprehensively adjusting the response lag of demand and control commands, the parameter optimization coefficients of the integrated industrial simulation control system are obtained.

[0070] Specifically, the corresponding calculation formula is: in, Represents the parameter optimization coefficients of an integrated industrial simulation control system; This represents the average response lag of control commands over multiple monitoring time periods. This indicates the average value of adjusted demand over multiple monitoring periods; This represents the hyperbolic tangent function.

[0071] Provide an explanation. This represents the average response lag of control commands, used as the cumulative error for an integrated industrial simulation control system. This represents the average value of the adjustment demand, which reflects the cumulative demand of the conveyor belt during operation. The larger the value, the more likely it is that during the operation of the conveyor belt, up to the current monitoring period, the tension setting of the conveyor belt is insufficient to adapt to the changes in the load on the conveyor belt. In other words, the tension setting in the current monitoring period is improper, causing items to slip or get stuck. This indicates that the parameters of the integrated industrial simulation control system need to be adjusted in a timely manner to respond to changes in the load on the conveyor belt and avoid potential production interruptions.

[0072] Step S32: Combine the parameter optimization coefficients of the integrated industrial simulation control system with the original proportional gain value of the control unit to obtain the adjusted proportional gain value, and feed it back to the control unit to construct different scenarios for simulation testing and dynamically adjust the tension of the conveyor belt.

[0073] Specifically, the adjusted proportional gain value is obtained by multiplying the parameter optimization coefficients by the original proportional gain value of the control unit used in the current simulation environment, i.e., the PID controller, and then fed back to the PID controller chip. The proportional gain value is adjusted by parameter optimization coefficients determined by various factors, and different scenarios are constructed for simulation testing to dynamically adjust the tension of the conveyor belt in order to achieve efficient and stable control.

[0074] To better illustrate this, in the integrated industrial simulation control system, the adjusted PID controller is simulated and tested to ensure that the new proportional gain value can effectively improve system performance. The simulation process should include different load change scenarios to verify the robustness and adaptability of the controller. Furthermore, the tension of the conveyor belt is dynamically adjusted to obtain the optimized control unit parameters, which are then applied to actual industrial equipment. The response of the industrial equipment is monitored in real time, including indicators such as response time, steady-state error, and overshoot. Based on real-time data and feedback information, the parameters of the PID controller are further fine-tuned to adapt to possible changes in the production environment.

[0075] The modeling and simulation of the entire integrated industrial simulation control system in a virtual simulation environment allows operators to evaluate the effects of different control strategies and parameter configurations, ensuring the effectiveness of the optimization scheme before actual deployment. Multiple industrial devices, i.e., various industrial control modules, are integrated into the same simulation platform to observe the synergistic effects of the overall process, ensuring that adjustments to the control unit, i.e., the PID controller, do not have a negative impact on other systems. Finally, by combining big data analytics and IoT technology, real-time monitoring data is integrated into the integrated industrial simulation control system to support the optimization of the control unit, forming a closed-loop control system.

[0076] Understandably, an integrated industrial simulation control system is formed by integrating the operation module, data analysis and processing module, and data adjustment module. Based on monitoring data, the tension changes of the conveyor belt are determined, revealing the possibility of improper conveyor belt tension settings. Then, based on the efficiency of the operation module in processing items, combined with the possibility of improper conveyor belt tension settings, the adjustment requirements of the integrated industrial simulation control system are analyzed. Next, the response time of control commands is analyzed to obtain response lag. Finally, the parameter optimization coefficients in the integrated industrial simulation control system are obtained. The tension of the conveyor belt is dynamically adjusted by the control unit to ensure that the integrated industrial simulation control system can respond promptly to load changes on the conveyor belt. Through continuous feedback and optimization, the system adapts to constantly changing production demands, achieving efficient and stable industrial control objectives.

[0077] The second embodiment of this invention proposes an integrated industrial simulation control device, including: a processor, a communication interface, a memory, and a communication bus. The processor, communication interface, and memory communicate with each other through the communication bus. The processor calls logical instructions in the memory to execute an integrated industrial simulation control system as described in any of the foregoing embodiments. This device has the same beneficial effects as the aforementioned integrated industrial simulation control system, and will not be described in detail here.

[0078] Understandably, when an integrated industrial simulation control device's processor, communication interface, memory, and communication bus are in operation, they need to utilize an integrated industrial simulation control system provided in any of the foregoing embodiments. Therefore, whether the method or system is integrated with program data or different hardware is configured to produce functions similar to those achieved by the present invention, they all fall within the protection scope of the present invention.

[0079] It should be noted that the order of the above embodiments of the present invention is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. The processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0080] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

Claims

1. An integrated industrial simulation control system for simulating and controlling sorting and conveying tasks, characterized in that, The system includes: The operation module is used to: perform sorting and transfer tasks, and acquire monitoring data during the sorting and transfer process; The data analysis and processing module is used to: analyze the tension changes of the integrated industrial simulation control system based on monitoring data to obtain adjustment requirements; issue control commands based on adjustment requirements; analyze the response time of the control commands to obtain the response hysteresis of the control commands; The data adjustment module is used to comprehensively adjust the response lag of demand and control commands, obtain the parameter optimization coefficients of the integrated industrial simulation control system, and feed them back to the operation module, so as to dynamically adjust the tension in sorting and transmission tasks through the operation module.

2. The integrated industrial simulation control system as described in claim 1, characterized in that, The operation module includes a control unit and a conveyor belt, sensors, and sorting equipment electrically connected to the control unit. The sensors are installed on the conveyor belt and collect monitoring data from the conveyor belt and upload it to the control unit. The sorting point is determined based on the conveyor belt. The sorting equipment is set close to the sorting point and records the success rate of sorting items and the item transit time, which is then uploaded to the control unit. The control unit controls the operation of the conveyor belt based on the monitoring data, the success rate of sorting items, and the item transit time.

3. An integrated industrial simulation control system as described in claim 2, characterized in that, The monitoring data includes tension monitoring data, current monitoring data, and weight monitoring data.

4. An integrated industrial simulation control system as described in claim 3, characterized in that, Based on the analysis of monitoring data and the tension changes in the integrated industrial simulation control system, adjustment requirements are derived, including: The expected tension range is preset and compared with tension monitoring data to determine the tension changes of the conveyor belt. Combined with current monitoring data, the possibility of improper conveyor belt tension setting is obtained. Based on the success rate of sorting items and the time it takes for items to pass through, the efficiency of the sorting equipment in sorting items is judged, and the adjustment requirements are determined.

5. An integrated industrial simulation control system as described in claim 4, characterized in that, A preset tension expectation range is established and compared with tension monitoring data to determine the tension variation of the conveyor belt. Combined with current monitoring data, the possible causes of improper conveyor belt tension settings are identified, including: The complexity of the conveyor belt tension variation is determined by the expected tension range and tension monitoring data, and a judgment threshold is set. If the complexity of the conveyor belt tension variation is greater than the judgment threshold, it indicates that there is an inappropriate change in the tension of the conveyor belt. The current expectation range is preset. If the current monitoring data at the current monitoring time is within the current expectation range, and the current monitoring data at the next adjacent monitoring time is outside the current expectation range, it indicates a sudden change in current. When there are inappropriate changes in the tension of the conveyor belt and a sudden change in the current, the possibility of improper conveyor belt tension setting is quantified by combining the current monitoring data at the corresponding two monitoring times with the complexity of the conveyor belt tension change.

6. An integrated industrial simulation control system as described in claim 4, characterized in that, Based on the success rate of sorting items and the time it takes for items to pass through, the efficiency of the sorting equipment is determined, and the adjustment requirements are identified, specifically: The efficiency of the sorting equipment is determined based on the success rate of sorting items and the time it takes for items to pass through. A screening threshold is set. When the efficiency of the sorting equipment is less than the screening threshold, the efficiency of the sorting equipment is combined with the possibility of improper conveyor belt tension settings to determine the adjustment requirements for the conveyor belt tension.

7. An integrated industrial simulation control system as described in claim 3, characterized in that, Based on the adjustment requirements, control commands are issued. The response time of the control commands is analyzed to obtain the response lag of the control commands, including: Based on the adjustment requirements, control commands are issued, and the time difference between issuing the control command and the conveyor belt receiving the control command is recorded. Based on weight monitoring data and tension monitoring data, the corresponding weight changes and tension changes are determined, and the response lag of control commands is determined by combining the time difference.

8. An integrated industrial simulation control system as described in claim 7, characterized in that, Based on the weight monitoring data and tension monitoring data, the corresponding weight changes and tension changes are determined as follows: Based on the weight monitoring data and tension monitoring data, corresponding weight monitoring curves and tension monitoring curves are obtained. The slope is determined by the monitoring data at any two adjacent monitoring time points in the curves, and the slope is analyzed to assess the synchronicity between weight changes and tension changes.

9. An integrated industrial simulation control system as described in claim 2, characterized in that, By comprehensively adjusting the response lag of demand and control commands, the parameter optimization coefficients of the integrated industrial simulation control system are obtained and fed back to the operation module. The operation module dynamically adjusts the tension in sorting and transmission tasks, including: By comprehensively adjusting the response lag of demand and control commands, the parameter optimization coefficients of the integrated industrial simulation control system are obtained. By combining the parameter optimization coefficients of the integrated industrial simulation control system with the original proportional gain value of the control unit, the adjusted proportional gain value is obtained and fed back to the control unit. Different scenarios are constructed for simulation testing to dynamically adjust the tension of the conveyor belt.

10. An integrated industrial simulation control device, characterized in that, include: The system includes a processor, a communication interface, a memory, and a communication bus. The processor, communication interface, and memory communicate with each other via the communication bus. The processor calls logical instructions from the memory to execute an integrated industrial simulation control system as described in any one of claims 1 to 9.

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