Automatic production line three-dimensional simulation debugging and monitoring method

Abstract

The invention discloses an automatic production line three-dimensional simulation debugging and monitoring method, and relates to the technical field of industrial simulation, and the method comprises the steps: carrying out the modularization modeling, motion and sensing configuration and process sequence arrangement of a production line assembly on a three-dimensional simulation platform, and obtaining a simulation engineering package, a process sequence table and a port dictionary; mapping the port dictionary into an object, a variable and an event node of a unified architecture address space, and solidifying a namespace version to generate a binding table; and controlling engineering variable unification according to the port dictionary drive, performing unified architecture subscription release configuration according to the binding table, executing virtual joint debugging, and collecting address space variable change records and event node trigger records to form an event mirror image volume and three-party version fingerprints. According to the method, the event mirror image volume, the namespace version, the virtual controller project version and the simulation project package version form a three-party version fingerprint, and fixed-point correction and namespace version incremental of the control project and the simulation project are achieved.

Description

Technical Field

[0001] This invention relates to the field of industrial simulation technology, and in particular to a method for three-dimensional simulation debugging and monitoring of automated production lines. Background Technology

[0002] As discrete manufacturing evolves towards flexibility and multi-variety, small-batch production, the virtual commissioning of automated production lines has gradually evolved from single-machine-level simulation to three-dimensional simulation and control engineering integration for the entire line. Common practices include completing component-based modeling, motion constraints, and sensor configuration of production line assemblies on a three-dimensional simulation platform, and publishing device objects, variables, and event nodes in the address space using a unified architecture communication to achieve signal interaction between the virtual controller engineering and the simulation engineering package. At the same time, subscription and publish configuration is completed through the integration and monitoring gateway to support integration and online monitoring.

[0003] Existing solutions still have shortcomings in multi-source engineering collaboration and lifecycle traceability: First, the semantic alignment between simulation signals, control variables and address space nodes often relies on manual naming or scattered mapping, which can easily lead to port mismatch and node missingness, resulting in limited integration convergence speed; Second, integration and field operation often lack reproducible event-level evidence chains, and anomaly localization relies on experience backtracking, making it difficult to establish a deterministic association between the state advancement of the process sequence table and variable changes and event triggers, thereby reducing the consistency and efficiency of version locking and cross-scenario reproduction. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, this invention provides a method for 3D simulation debugging and monitoring of automated production lines to solve the problem of semantic inconsistency and difficulty in traceability and reproduction between 3D simulation, control engineering and unified architecture address space.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: This invention provides a method for three-dimensional simulation debugging and monitoring of automated production lines, which includes completing component modeling, motion and sensor configuration and process sequence arrangement of the production line assembly on a three-dimensional simulation platform to obtain a simulation engineering package, a process sequence table and a port dictionary; Map the port dictionary to objects, variables and event nodes in a unified architecture address space and fix the namespace version to generate a binding table; Based on the port dictionary, the control engineering variables are made consistent and the unified architecture subscription and publication configuration is performed according to the binding table. Virtual joint debugging is performed and address space variable change records and event node trigger records are collected to form event mirror volume and third-party version fingerprint. Perform consistency audits on the event mirror volume according to node type and process sequence list, locate deviation nodes, complete the fixed-point correction of control engineering and simulation engineering, and increment the namespace version to obtain the corrected node set file and project package. Deploy the revised node set files and project packages to the site and lock the version. Continuously archive site event images and perform offline replay to reproduce and diagnose, forming a monitoring and traceability library.

[0007] As a preferred embodiment of the three-dimensional simulation debugging and monitoring method for automated production lines described in this invention, the acquisition of the simulation engineering package, process sequence table, and port dictionary specifically includes: The 3D simulation platform is imported into the production line assembly and the components are broken down into sorting units, sorting channels, packing units, and conveying units to obtain a component list. Configure motion constraints, actuators, and positioning and occupancy sensors for each component in the component list to obtain the electromechanical configuration table; The actuators and sensors in the electromechanical configuration table are arranged and connected in series according to the order of sorting, sorting, and packing operations to obtain the process sequence table; The actuator and sensor signals corresponding to the process sequence table are summarized, and the port name, direction, data type, engineering unit, triggering method and process segment are recorded to obtain the port dictionary; The component list, electromechanical configuration table, process sequence table, and port dictionary are encapsulated to form a simulation project package.

[0008] As a preferred embodiment of the three-dimensional simulation debugging and monitoring method for automated production lines described in this invention, the generation of the binding table specifically involves: The port dictionary is grouped by device type and the object type templates of the transmission unit, the channel execution unit, the grab and transport unit, and the packaging unit are extracted to obtain the object type table. Configure a set of variable nodes and a set of event nodes for each object type according to the object type table, and complete the missing nodes according to the object type template to obtain the node type definition; Based on the node type definition, the node allocation table is obtained by assigning each port to an object, node category, and node identifier in the port dictionary. The namespace version is fixed based on the node allocation table and a node set file is generated. At the same time, the node set file is loaded on the unified architecture server and the address space is published to obtain the effective address space. Based on the effective address space, a one-to-one correspondence is established between the node identifier and the port name in the port dictionary, and the binding table from port to node is output.

[0009] As a preferred embodiment of the three-dimensional simulation debugging and monitoring method for automated production lines described in this invention, the namespace version is obtained by numbering the node allocation table generated from the port dictionary using a preset version encoding rule and registering it as a namespace identifier.

[0010] As a preferred embodiment of the three-dimensional simulation debugging and monitoring method for automated production lines described in this invention, the step of driving the consistency of control engineering variables based on the port dictionary specifically includes: Convert the port dictionary into a control engineering variable table while keeping the port names consistent with the variable names to obtain a variable consistency list; The variable uniformity list is divided into control output set and control input set according to direction and data type, resulting in a variable grouping table; Write the variable grouping table into the control project and complete the compilation and download to obtain the virtual controller project.

[0011] As a preferred embodiment of the automated production line 3D simulation debugging and monitoring method of the present invention, wherein: the unified architecture subscription and publication configuration based on the binding table specifically includes: Organize the binding table into a list of subscription objects and label the variable nodes and event nodes corresponding to the control inputs to form the subscription configuration; Organize the binding table into a list of published objects and mark the variable nodes corresponding to the control output to form the published configuration; Load the subscription and publishing configurations into the joint debugging monitoring gateway and enable the session connection to obtain the joint debugging channel.

[0012] As a preferred embodiment of the automated production line 3D simulation debugging and monitoring method of the present invention, wherein: the formation of the event mirror volume and the third-party version fingerprint specifically includes: The virtual controller project and simulation project package are connected through the joint debugging channel, and the actuator actions are triggered according to the process sequence table to obtain the virtual joint debugging operation state; The virtual joint debugging running state is used to synchronously collect address space variable change records and event node trigger records, and arrange them in chronological order to obtain an event sequence; The namespace version, virtual controller project version, and simulation project package version are used as version fingerprints and associated with the event sequence to form an event mirror volume and third-party version fingerprints.

[0013] As a preferred embodiment of the automated production line 3D simulation debugging and monitoring method of the present invention, the step of performing consistency auditing on the event mirror volume according to node type and process sequence table and locating deviation nodes specifically includes: The event mirror volume is parsed into object-level event traces according to node type definition and the correspondence between variable nodes and event nodes is preserved to obtain the audit trace set; The audit trajectory set is checked against the sorting, sorting, and packing status progression order according to the process sequence table, and inconsistent sections are marked to obtain the deviation section table; The deviation segment table is associated with the binding table, and the specific object type, node identifier, and port identifier are located to obtain the deviation node list.

[0014] As a preferred embodiment of the three-dimensional simulation debugging and monitoring method for automated production lines described in this invention, the method for obtaining the corrected node set file and project package specifically includes: The list of deviation nodes is broken down into control engineering correction items and simulation engineering correction items, which are respectively pointed to interlocking relationships, counting triggering relationships, motion holding relationships, actuator stroke, initial pose, sensor installation position, and sequence segment trigger point to obtain the correction task table. Update the virtual controller project and simulation project package according to the revised task list, and complete the recompiling and reloading to obtain the revised project package; Based on the revised project package, the namespace version is incremented and the node set file is regenerated to form the revised node set file and project package.

[0015] As a preferred embodiment of the three-dimensional simulation debugging and monitoring method for automated production lines described in this invention, the formation of the monitoring and traceability database specifically includes: The revised node set file and project package are distributed to the field monitoring gateway and field controller, and the unified architecture address space is enabled to obtain the field version locked state. Based on the on-site version locked state continuous archive address space variable change records and event node trigger records, and divided into volumes according to the third-party version fingerprint, the on-site event archive volume is obtained; The on-site event archive triggers offline replay and links the simulation engineering package and virtual controller engineering to reproduce the process sequence, thus obtaining a reproduction diagnostic volume; The on-site event archive, the reproduction diagnostics archive, and the namespace version sequence are combined to form a monitoring and traceability library.

[0016] The beneficial effects of this invention are as follows: The port dictionary serves as a unified semantic carrier spanning the simulation engineering package, control engineering variable table, and unified architecture address space. Through object type templates and node type definitions, the port dictionary is deterministically mapped to objects, variables, and event nodes. A node allocation table solidifies the namespace version and forms a port-to-node binding table, ensuring a verifiable correspondence between subscription and publish configurations. This reduces instability caused by port mismatches and missing nodes from the source. During joint debugging, address space variable change records and event node trigger records are aggregated to form an event mirror volume. This mirror volume, along with the namespace version, virtual controller engineering version, and simulation engineering package version, constitutes a three-way version fingerprint. This allows consistency auditing to quickly locate deviation nodes and output correction task tables under the action segment sequence constraints of the process sequence table, achieving point-to-point correction of control engineering and simulation engineering, and namespace version incrementing. Under the locked state of the field version, a field event archive volume is continuously formed, triggering offline replay to generate a reproducible diagnostic volume, constructing a monitoring and traceability library. This significantly improves reproducibility consistency and diagnostic efficiency across versions and scenarios. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. 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.

[0018] Figure 1 This is a flowchart of a method for 3D simulation debugging and monitoring of automated production lines.

[0019] Figure 2 Flowchart for generating the binding table.

[0020] Figure 3 This is a flowchart for virtual integration testing and record collection.

[0021] Figure 4 This is a flowchart for consistency audit and correction. Detailed Implementation

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0023] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0024] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0025] Reference Figures 1-4 This is one embodiment of the present invention, which provides a method for three-dimensional simulation debugging and monitoring of an automated production line, including the following steps: S1. Complete the component-based modeling, motion and sensing configuration, and process sequence arrangement of the production line assembly on the 3D simulation platform to obtain the simulation engineering package, process sequence table, and port dictionary.

[0026] S1.1. The 3D simulation platform opens the import interface and loads the production line assembly. The 3D simulation platform displays the hierarchical structure of the production line assembly in the scene tree. The 3D simulation platform decomposes the production line assembly into components according to four types of objects: sorting unit, sorting channel unit, packing unit, and conveying unit. The component decomposition results form sub-levels of the four types of objects in the scene tree. The 3D simulation platform extracts the component name and component type item by item from the sub-level of each type of object and forms a list record. The list record contains complete entries of sorting unit components, sorting channel components, packing unit components, and conveying unit components. The list record forms a component list.

[0027] S1.2. Select each component from the component list and enter the attribute configuration interface. The 3D simulation platform configures three types of elements at the component level: motion constraints, actuators, and positioning and occupancy sensors. Motion constraints are used to limit the allowed relative motion relationships between components. Motion constraints include common mechanism constraint forms such as fixed constraints, rotational constraints, and linear constraints. The motion constraint configuration results correspond to the degree of freedom range and motion direction of the component. Actuators are used to drive the components that satisfy the motion constraints to move. The actuator configuration includes the actuator name, controlled component, motion direction, and target quantity type. Positioning and occupancy sensors are used to reflect the process position status. The positioning and occupancy sensor configuration includes the sensor name, detection position, trigger condition, and output signal type. The 3D simulation platform registers the motion constraint configuration results, actuator configuration results, and positioning and occupancy sensor configuration results by component name, line by line, to form an electromechanical configuration table.

[0028] S1.3. Based on the electromechanical configuration table, select the actuators and positioning / occupancy sensors corresponding to the sorting unit and define the sorting action segments. Each sorting action segment includes the sorting action trigger condition, sorting action duration condition, and sorting action end condition. Based on the electromechanical configuration table, select the actuators and positioning / occupancy sensors corresponding to the lane-separating unit and define the lane-separating action segments. Each lane-separating action segment includes the lane-separating action trigger condition, lane-separating action duration condition, and lane-separating action end condition. Based on the electromechanical configuration table, select the actuators and positioning / occupancy sensors corresponding to the packing unit and define the packing action segments. Each packing action segment includes the packing action trigger condition, packing action duration condition, and packing action end condition. The 3D simulation platform connects the sorting action segments, lane-separating action segments, and packing action segments in sequence according to the order of sorting, lane-separating, and packing operations. The connection relationship is expressed using the correspondence between the end condition of the previous action segment and the trigger condition of the next action segment. The sequence of connected action segments forms a process sequence table.

[0029] S1.4. Extract the actuator signals and sensor signals associated with each action segment from the process sequence list and form a signal list. The signal list contains actuator signal entries and sensor signal entries. The 3D simulation platform registers the port information for each signal in the signal list. The port name uses a unique naming rule formed by combining the action segment name, actuator name, and position / occupancy sensor name from the process sequence list. The port direction is used to distinguish between the actuator signal direction and the sensor signal direction. The data type is registered according to Boolean and numerical values. For numerical values, the engineering unit is registered as commonly used process units such as millimeters and millimeters per second. The triggering method is registered as level triggering and edge triggering. The process segment is registered as sorting action segment, sorting action segment, and packing action segment. The complete registration result of the port information forms a port dictionary.

[0030] The 3D simulation platform unifies the component list, electromechanical configuration table, process sequence table, and port dictionary into a single project directory structure. The project directory structure includes scene files, configuration table files, and sequence table files. The configuration table files correspond to the electromechanical configuration table and the port dictionary, and the sequence table files correspond to the process sequence table. The 3D simulation platform encapsulates the project directory structure and generates a package file. The package file maintains consistent naming and version identification for the component list, electromechanical configuration table, process sequence table, and port dictionary, forming a simulation project package.

[0031] S2. Map the port dictionary to objects, variables and event nodes in a unified architecture address space and fix the namespace version to generate a binding table.

[0032] S2.1. Perform a grouping operation on the port dictionary according to the device type. The device type grouping result shall include at least four types of groups: transmission unit, channel execution unit, grab and transport unit, and packaging unit. The device type grouping result shall form a device type grouping table. The device type grouping table shall record the port name set, direction, data type, engineering unit, triggering method and process segment corresponding to each group.

[0033] The object type templates for the equipment type grouping table are extracted from the following groups: the object type templates for the conveying unit, the object type templates for the channel execution unit, the object type templates for the grabbing and handling unit, and the object type templates for the packaging unit. Each object type template records the object type name, the set of port names included in the object type, and the port direction. The four types of object type templates are summarized to form the object type table.

[0034] S2.2. The object type table includes a set of configuration variable nodes and a set of event nodes for each object type. The set of variable nodes is used to express the port status in the port dictionary where the data type is Boolean or numeric. The set of event nodes is used to express the port triggering record in the port dictionary where the triggering method is edge triggering. The set of variable nodes and the set of event nodes record the node name, node direction, and node data type, respectively. A missing node completion operation is performed on each object type through the object type table. The missing node completion operation checks the node names in the set of variable nodes and the set of event nodes item by item according to the set of port names in the object type template. After the missing node completion operation is completed, the node type definition is obtained.

[0035] To further explain, the missing node determination adopts the port name consistency check rule: for each port name in the object type template, a node name with the same name is searched in the variable node set and the event node set. The port name for which no node name with the same name is found is determined to be the port name corresponding to the missing node. The missing node completion determination adopts the trigger mode and data type consistency completion rule: if the port name corresponding to the missing node has an edge trigger mode in the port dictionary, it is completed as an event node and the node name is registered as the port name, the node direction is the port direction, and the node data type is the port data type. If the port name corresponding to the missing node has a level trigger mode in the port dictionary, it is completed as a variable node and the node name is registered as the port name, the node direction is the port direction, and the node data type is the port data type. After completion, the port name set is checked again item by item until there is no port name for which no node name with the same name is found.

[0036] S2.3. Object attribution is assigned to each port in the port dictionary using node type definitions. This assignment categorizes port names into one of four object types: transmission unit, distribution execution unit, grabbing and handling unit, and packaging unit, according to the device type grouping table. Node category assignment is also performed on each port in the port dictionary using node type definitions. This allocation assigns port names as variable nodes or event nodes based on data type and triggering method. Finally, node identifier assignment is performed on each port in the port dictionary using node type definitions. This assignment uses node identifier encoding and records the correspondence between node identifiers and port names. Node identifiers are used to uniquely locate objects, variables, and event nodes in the unified architecture address space. After node identifier assignment, a node allocation table is formed.

[0037] Perform a namespace version numbering operation on the node allocation table. The namespace version numbering operation assigns a value to the version number field of the node allocation table and registers it as a namespace identifier using version encoding rules. The version encoding rules use an integer incrementing method to express the order of namespace versions. The namespace identifier forms the namespace version. The node allocation table, together with the namespace version, generates a node set file.

[0038] To further explain, the version encoding rule adopts a three-segment decimal string format of major version number, minor version number, and revision number. The major version number is used to indicate the version advancement when the object type table or node type definition changes. The minor version number is used to indicate the version advancement when the port name set in the node allocation table is added or deleted. The revision number is used to indicate the version advancement when the node identifier allocation or node name registration is adjusted. The three-segment decimal string format corresponds one-to-one with the version number field of the node allocation table and is registered as a namespace identifier on the unified architecture server.

[0039] S2.4. Perform a node set file loading operation on the unified architecture server. The node set file loading operation establishes an object hierarchy consistent with the object type table on the unified architecture server, and creates variable nodes and event nodes consistent with the node allocation table under the object hierarchy. At the same time, it registers the namespace version on the unified architecture server and completes the address space publication to form an effective address space.

[0040] The effective address space retrieves node identifiers item by item according to the node allocation table and reads the corresponding node name and node category. The effective address space performs a one-to-one correspondence registration between the node identifier and the port name in the port dictionary, including the port name, node identifier, object affiliation and node category fields, and outputs the port to node binding table.

[0041] S3. Based on the port dictionary, drive the consistency of engineering variables and perform unified architecture subscription and publication configuration according to the binding table. Perform virtual joint debugging and collect address space variable change records and event node trigger records to form event mirror volume and third-party version fingerprint.

[0042] S3.1. Perform a control engineering variable table conversion operation on the port dictionary, register the port names in the port dictionary as variable names according to the same name rule, register the directions in the port dictionary as variable directions, register the data types in the port dictionary as variable data types, register the engineering units in the port dictionary as variable engineering units, and register the triggering methods and their respective work segments in the port dictionary as variable description information. The registration results form a variable consistency list.

[0043] Perform variable grouping operation on the variable consistency list, divide the control output set and control input set according to the direction and data type in the port dictionary. The control output set corresponds to the variable entries of actuator signals, and the control input set corresponds to the variable entries of position and place sensor signals. The variable grouping operation also retains the same name relationship between port name and variable name and registers the variable direction and variable data type to form a variable grouping table.

[0044] S3.2. Perform control project configuration operation on the variable grouping table, configure each variable entry in the variable grouping table to the control project and keep the variable name consistent with the port name. After the control project configuration operation is completed, perform control project compilation operation and generate virtual controller project version. After the control project compilation operation is completed, perform control project download operation and deploy it to the virtual controller environment to obtain the virtual controller project.

[0045] The subscription object list is organized by performing a subscription object list operation on the binding table. Entries with node categories of variable node and event node are filtered from the binding table and matched against the control input set in the variable grouping table by port name. The port name, node identifier, node category, and object ownership fields are recorded to form the subscription object list. The publishing object list is organized by performing a publishing object list operation on the binding table. Entries with node category of variable node are filtered from the binding table and matched against the control output set in the variable grouping table by port name. The port name, node identifier, and object ownership fields are recorded to form the publishing object list. The subscription configuration and publishing configuration are loaded and configured to the joint debugging monitoring gateway. The joint debugging monitoring gateway performs a session connection operation and maintains communication with the unified architecture server to form a joint debugging channel.

[0046] S3.3. Perform a connection operation on the joint debugging channel and complete the communication connection between the virtual controller project and the simulation project package. The virtual controller project writes the variable values ​​corresponding to the control output set into the variable nodes of the unified architecture address space by publishing the configuration. The simulation project package receives the actuator drive quantity according to the variable nodes of the unified architecture address space and drives the actuator to complete the movement within the motion constraint range. It generates sensor signals according to the detection position of the position and occupancy type sensors and updates the variable nodes and event nodes of the unified architecture address space. The virtual controller project receives the variable node change notification and event node trigger notification of the unified architecture address space by subscribing to the configuration. After the communication connection is completed, the actuator action is triggered according to the process sequence table and a virtual joint debugging running state is formed.

[0047] The virtual joint debugging operation performs a record collection operation. This operation notifies variable nodes of changes in the unified architecture address space, forming address space variable change records. The record fields include port name, node identifier, variable value, timestamp, and node category. The record collection operation also notifies event nodes of triggers in the unified architecture address space, forming event node trigger records. The record fields include port name, node identifier, trigger status, timestamp, and node category. The address space variable change records and event node trigger records are arranged in timestamp order to form an event sequence.

[0048] The event sequence is associated with a version fingerprint. The namespace version registered by the unified architecture server is extracted and registered as the namespace version field. The virtual controller project version generated by the downloaded virtual controller project is extracted and registered as the virtual controller project version field. The version identifier carried by the simulation project package encapsulation file is extracted and registered as the simulation project package version field. The namespace version field, the virtual controller project version field and the simulation project package version field are combined to form a third-party version fingerprint. The third-party version fingerprint and the event sequence are encapsulated together to form an event mirror volume.

[0049] S4. Perform a consistency audit on the event mirror volume according to the node type and process sequence list, locate the deviation nodes, complete the fixed-point correction of the control engineering and simulation engineering, and increment the namespace version to obtain the corrected node set file and project package.

[0050] S4.1. Unpack the event mirror volume to obtain the event sequence and third-party version fingerprint. Reorganize the event sequence into object-level event traces according to object affiliation by defining node types and maintain the correspondence between node identifiers and port names in the port dictionary to form an audit trace set. Summarize the node type definitions to obtain the set of required node identifiers and enumerate the effective address space to obtain the set of published node identifiers.

[0051] To further explain, the set of required node identifiers and the set of published node identifiers are used to calculate the number of missing nodes, expressed as: ; in, A set of required node identifiers representing a summary of node type definitions; Represents the set of published node identifiers for the effective address space enumeration; This represents the set difference operation; Indicates the number of elements in the set; Indicates the number of missing nodes, used to mark nodes in the audit trajectory set to identify the missing associated object and node category information.

[0052] S4.2. Map the event sequence to the observed action segment sequence according to the action segment order of the process sequence table. The process sequence table is directly used as the expected action segment sequence. Check the observed action segment sequence and the expected action segment sequence item by item to obtain the inconsistency position set. The timestamp interval corresponding to the inconsistency position set is registered as the deviation segment table.

[0053] To further explain, the inconsistency count between the observed action sequence and the expected action sequence is obtained by item-by-item comparison, expressed as: ; in, Indicates the number of action segments involved in the verification; Represents the first segment of the expected action sequence Each action segment name is derived from the process sequence list; Represents the first action segment sequence observed. Each action segment name is derived from the event sequence mapping of the audit trajectory set; This indicates an indicator function; the value is 1 if the condition is true and 0 if the condition is false. This represents the inconsistency count. The set of inconsistency locations corresponding to the inconsistency count is used to generate the inconsistency segment entries in the deviation segment table.

[0054] S4.3. Associate each deviation segment table with the node identifier and timestamp interval of the audit trajectory set. The node identifiers of variable node change records or event node trigger records that occur within the timestamp interval form a candidate node set. The port-to-node binding table reverse-checks the port name and object attribution in the port dictionary for each candidate node set and registers the node category to form a deviation node list. The deviation node list fields include object type, node identifier, port name, node category and deviation segment number.

[0055] The deviation node list is divided into control engineering correction items and simulation engineering correction items according to object type and node category. The control engineering correction items register the correction content of interlocking relationship, counting trigger relationship and action holding relationship according to the deviation section table. The simulation engineering correction items register the correction content of actuator stroke, initial pose, sensor installation position and sequence segment trigger point according to the deviation section table, forming a correction task table. The fields of the correction task table include the node identifier and port name correspondence of the deviation node list and the correction content type.

[0056] The task table-driven control project performs fixed-point modifications to the interlocking relationships, counting trigger relationships, and motion holding relationships in the control project corresponding to the virtual controller project version, and completes compilation and download. The task table-driven simulation project package performs fixed-point modifications to the actuator stroke, initial pose, sensor installation position, and sequence segment trigger point, and completes encapsulation to form the corrected project package. The node allocation table corresponding to the corrected project package performs namespace version increment and generates node set files.

[0057] S5. Deploy the revised node set file and project package to the site and lock the version. Continuously archive the site event images and perform offline replay to reproduce and diagnose, forming a monitoring and traceability library.

[0058] S5.1. The field monitoring gateway receives the corrected node set file and completes its loading, registers the namespace version corresponding to the corrected node set file, and publishes the unified architecture address space; the field controller receives the corrected project package and completes its deployment, enables unified architecture address space communication, and maintains consistent namespace versions; it performs lock registration on the namespace version and performs validity marking on the node set publication status of the unified architecture address space, forming a field version lock state.

[0059] In the field version-locked state, the field monitoring gateway generates address space variable change records based on variable node changes in the unified architecture address space. These records include fields for port name, node identifier, variable value, timestamp, and node category. The field monitoring gateway performs version fingerprint association registration for each address space variable change record and each event node trigger record. This registration reads the namespace version from the field version-locked state, the field controller project version from the field controller registration, and the simulation project package version from the project package deployment registration, combining them to form a third-party version fingerprint. This third-party version fingerprint is then appended as a header field to both the address space variable change record and the event node trigger record. The system records and maintains the port name and node identifier unchanged, ensuring that the address space variable change records and event node trigger records have the same version attribution identifier as the on-site version lock state. The on-site monitoring gateway further executes the same version aggregation rule on the address space variable change records and event node trigger records. The same version aggregation rule divides the records into the same attribution set according to the third-party version fingerprint field, and arranges them in the order of timestamps within each attribution set to form an on-site event sequence. This allows the on-site event sequence to carry semantic positioning information of port name, node identifier, and node category, as well as version positioning information of third-party version fingerprint. The on-site monitoring gateway will then divide and archive the on-site event sequences carrying the third-party version fingerprint field and generate an on-site event archive volume.

[0060] S5.2. Perform offline replay operation on the field event archive. The offline replay operation starts the unified architecture server in the offline environment and loads the corrected node set file. The offline environment publishes the unified architecture address space consistent with the namespace version. The offline environment deploys the virtual controller project and simulation project package. The offline environment enables unified architecture address space communication and keeps the port name consistent with the node identifier. Replay the address space variable change records and event node trigger records in the timestamp order of the field event archive. The replay results drive the virtual controller project and simulation project package to reproduce the actuator actions and position and occupancy sensor status changes corresponding to the process sequence table. The replay records and reproduction results of the reproduction process are collected to form a reproduction diagnostic volume.

[0061] The on-site event archive is archived according to the third-party version fingerprint and namespace version. The reproduction diagnostic volume is archived according to the third-party version fingerprint of the on-site event archive. The namespace version increment process is aggregated to form a namespace version sequence. The on-site event archive, reproduction diagnostic volume and namespace version sequence are aggregated, registered and formed into a monitoring and traceability database.

[0062] In summary, this invention uses a port dictionary as a unified semantic carrier that runs through the simulation engineering package, control engineering variable table, and unified architecture address space. It deterministically maps the port dictionary to objects, variables, and event nodes through object type templates and node type definitions. A node allocation table solidifies the namespace version and forms a port-to-node binding table, ensuring a verifiable correspondence between subscription and publish configurations. This reduces instability caused by port mismatches and missing nodes from the source. During joint debugging, address space variable change records and event node trigger records are collected to form an event mirror volume, which, along with the namespace version, virtual controller engineering version, and simulation engineering package version, constitutes a three-way version fingerprint. This allows consistency auditing to quickly locate deviation nodes and output correction task tables under the action segment sequence constraints of the process sequence table, achieving point-to-point correction of control engineering and simulation engineering and namespace version incrementing. Under the locked state of the field version, a field event archive volume is continuously formed, triggering offline replay to generate a reproducible diagnostic volume, constructing a monitoring and traceability library. This significantly improves reproducibility consistency and diagnostic efficiency across versions and scenarios.

[0063] Example 2, referring to Table 1, is the second embodiment of the present invention. To further verify the technical solution of the present invention, experimental simulation data of the three-dimensional simulation debugging and monitoring method for automated production lines are given.

[0064] The test subject is a discrete manufacturing production line consisting of a sorting unit, a sorting unit, a packing unit, and a conveying unit. The production line assembly contains actuator signals and position and occupancy sensor signals corresponding to 192 port name entries. The number of test cycles is set to 1000 cycles. The cycle start point is defined as the moment when the trigger condition of the sorting action segment is first met, and the cycle end point is defined as the moment when the end condition of the packing action segment is first met. The statistical window covers the complete timestamp interval of 1000 cycles. The experiment first imported the production line assembly into the 3D simulation platform and generated a component list. Each component in the list was configured with motion constraints, actuators, and positioning / occupancy sensors, and registered as an electromechanical configuration table. Then, based on the electromechanical configuration table, the sorting action segment, the sorting action segment, and the packing action segment were connected in sequence to form a process sequence table. The actuator and sensor signals corresponding to the process sequence table were then summarized and registered, including port name, direction, data type, engineering unit, triggering method, and the corresponding process segment, forming a port dictionary. The component list, electromechanical configuration table, process sequence table, and port dictionary were then packaged to obtain the simulation engineering package. The first round of joint debugging time was defined as the cumulative time from the moment the variable consistency list was generated until the moment the virtual joint debugging operation state first stably completed 10 consecutive cycles with a deviation segment count of 0.

[0065] The experiment then grouped the port dictionary by device type to form a device type grouping table. The device type grouping table extracted object type templates from the conveying unit, the sorting execution unit, the grabbing and handling unit, and the packaging unit, and summarized them to obtain an object type table. The object type table configured a variable node set and an event node set, and missing nodes were filled in to obtain the node type definition. Missing nodes were determined using a port name consistency check rule: if the port name of the object type template was not found in the variable node set or the event node set, it was considered a missing node. Missing node filling used a trigger mode consistency filling rule: edge-triggered nodes were filled as event nodes, and level-triggered nodes were filled as variable nodes. After filling, each item was checked again until no missing nodes remained. The node type definition assigns object ownership, node category, and node identifier to each port in the port dictionary, forming a node allocation table. This table then assigns namespace version numbers and generates a node set file. The namespace version number uses a three-part decimal string format: major version number, minor version number, and revision number. The major version number increments when the object type table changes, the minor version number increments when the port name set is added or deleted, and the revision number increments when the node identifier allocation is adjusted. The node set file is loaded onto the unified architecture server, and the address space is published to obtain the effective address space. The effective address space performs a one-to-one correspondence registration between node identifiers and port names in the port dictionary, resulting in a port-to-node binding table.

[0066] Finally, based on the port dictionary, the control engineering variables were standardized, resulting in a standardized variable list and a variable grouping table. The variable grouping table was used to compile and download the control engineering project to obtain the virtual controller project. The port-to-node binding table was organized to form a subscription object list and a publish object list, and the subscription configuration and publish configuration were loaded to form a joint debugging channel. The joint debugging channel established communication between the virtual controller project and the simulation project package and triggered actuator actions according to the process sequence table to form a virtual joint debugging running state. The virtual joint debugging running state collected address space variable change records and event node trigger records and formed an event sequence according to the timestamp order. The event sequence, namespace version, virtual controller project version, and simulation project package version formed a three-party version fingerprint and was encapsulated to obtain the event. Mirrored volumes; event mirrored volumes use an uncompressed row-based record format with timestamp precision in milliseconds. Address space variable change records and event node trigger records both include port name, node identifier, node category, and timestamp fields. The event mirrored volume capacity is calculated by dividing the number of bytes in the event mirrored volume file within the statistical window by the number of hours in the statistical window. The on-site event archive volume generation latency is defined as the time difference between a single record generating a notification from the unified architecture server and the on-site monitoring gateway completing the volume archiving and disk write, taken as the arithmetic mean of all records within the statistical window. The on-site anomaly reproduction success rate is defined as the percentage of times the offline replay of 100 anomaly trigger segments extracted from the statistical window completely matches the on-site deviation node list. A comparative experiment was conducted, setting up three existing methods as control groups and comparing them with the implementation method under the same total number of ports, the same process sequence table, and the same number of cycles. The control group did not generate event mirrored volumes or on-site event archive volumes, and the event mirrored volume capacity and the on-site event archive volume generation latency were recorded as 0. Details are shown in Table 1 below. Table 1. Comparison Data of Virtual and Real-World Coordination Consistency Verification parameter Comparison of A_manual variable mapping Compare B_script variable mapping Comparison of C_OPC variable subscription Implement 1_Port dictionary mapping Implement 2-node set version locking Implement 3_Event Mirroring Tracing Total number of ports 192 192 192 192 192 192 Number of port mismatches (locations) 14 9 7 2 1 0 The first round of joint testing took (in hours). 18.5 12.3 10.8 6.4 5.8 5.2 Process sequence deviation location time (minutes / location) 42 31 28 14 11 8 Number of deviation segments (segments / 1000 cycles) 23 18 15 9 7 6 Number of version lock failures (times / 100 deployments) 17 9 6 3 1 0 Success rate of on-site anomaly reproduction (%) 62 70 74 88 94 99 Time to generate a reproducible diagnostic questionnaire (minutes) 35 28 26 17 15 12 Event mirror volume capacity (MB / hour) 0 0 0 85 92 98 On-site event archive generation latency (ms) 0 0 0 18 22 25 The table above shows that the number of port mismatches and the time taken for the first round of joint debugging demonstrate the direct value of the port dictionary and binding table: Compared to manual variable mapping (A), there were still 14 port mismatches and the first round of joint debugging took 18.5 hours. Compared to script variable mapping (B) and unified architecture variable subscription (C), although the number of mismatches and time were reduced, there were still 9 and 7 mismatches respectively. Implementing port dictionary mapping (1) reduced the number of mismatches to 2, implementing node set version locking (2) reduced the number of mismatches to 1, and implementing event mirroring and tracing (3) achieved 0 mismatches. At the same time, the time taken for the first round of joint debugging was stabilized below 6.4 hours. This shows that the port name homonym rule of the port dictionary and the port-to-node binding table can significantly reduce the workload of the "variable alignment and debugging" stage and avoid structural mismatches caused by manual naming differences in the traditional method.

[0067] The process sequence deviation location time and the number of deviation segments demonstrate the operability of consistency auditing: Comparison A reached 42 minutes for each deviation location time and 23 deviation segments appeared in 1000 cycles, while Comparison B and Comparison C decreased to 31 minutes and 28 minutes respectively, but still maintained a high number of deviation segments; Implementing 3-event mirroring trace reduced the deviation location time to 8 minutes and controlled the number of deviation segments to 6 segments, indicating that after the event mirroring volume arranged the address space variable change records and event node trigger records into an event sequence with timestamps, the action segment sequence verification of the process sequence table can quickly limit the deviation segment range, making the location of the deviation node list more concentrated and reducing the non-deterministic process of "repeated reruns and blind checks".

[0068] The number of version locking failures and the success rate of reproducing on-site anomalies demonstrate the traceability effect of namespace versions: Compared to A, version locking failed 17 times in 100 deployments with a success rate of only 62% for reproducing on-site anomalies. Compared to B and C, there were improvements, but still 9 and 6 failures respectively. Implementing 2-node set version locking reduced the failure to 1 and increased the success rate of reproduction to 94%. Implementing 3-event mirroring further achieved 0 failures and a 99% success rate of reproduction. The additional overhead caused by the event mirror volume capacity and the latency of generating on-site event archive volumes remained within an acceptable range. The event mirror volume capacity was approximately 98MB per hour, and the archiving latency was approximately 25ms. This indicates that the formation of the monitoring and traceability library did not change the real-time joint debugging path driven by the process sequence list, but significantly enhanced the availability of on-site event archive volumes and reproduction diagnostic volumes. This clearly improved upon the shortcomings of existing technologies, which relied on manual repetition for reproduction and repeated trial runs for localization.

[0069] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for three-dimensional simulation debugging and monitoring of an automated production line, characterized in that: include, The production line assembly is modularly modeled, motion and sensor configuration is performed, and process sequence arrangement is completed on a 3D simulation platform to obtain a simulation engineering package, process sequence table, and port dictionary. Map the port dictionary to objects, variables and event nodes in a unified architecture address space and fix the namespace version to generate a binding table; Based on the port dictionary, the control engineering variables are made consistent and the unified architecture subscription and publication configuration is performed according to the binding table. Virtual joint debugging is performed and address space variable change records and event node trigger records are collected to form event mirror volume and third-party version fingerprint. Perform consistency audits on the event mirror volume according to node type and process sequence list, locate deviation nodes, complete the fixed-point correction of control engineering and simulation engineering, and increment the namespace version to obtain the corrected node set file and project package. Deploy the revised node set files and project packages to the site and lock the version. Continuously archive site event images and perform offline replay to reproduce and diagnose, forming a monitoring and traceability library.

2. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 1, characterized in that: The obtained simulation engineering package, process sequence table, and port dictionary are specifically as follows: The 3D simulation platform is imported into the production line assembly and the components are broken down into sorting units, sorting channels, packing units, and conveying units to obtain a component list. Configure motion constraints, actuators, and positioning and occupancy sensors for each component in the component list to obtain the electromechanical configuration table; The actuators and sensors in the electromechanical configuration table are arranged and connected in series according to the order of sorting, sorting, and packing operations to obtain the process sequence table; The actuator and sensor signals corresponding to the process sequence table are summarized, and the port name, direction, data type, engineering unit, triggering method and process segment are recorded to obtain the port dictionary; The component list, electromechanical configuration table, process sequence table, and port dictionary are encapsulated to form a simulation project package.

3. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 2, characterized in that: The generation of the binding table specifically involves: The port dictionary is grouped by device type and the object type templates of the transmission unit, the channel execution unit, the grab and transport unit, and the packaging unit are extracted to obtain the object type table. Configure a set of variable nodes and a set of event nodes for each object type according to the object type table, and complete the missing nodes according to the object type template to obtain the node type definition; Based on the node type definition, the node allocation table is obtained by assigning each port to an object, node category, and node identifier in the port dictionary. The namespace version is fixed based on the node allocation table and a node set file is generated. At the same time, the node set file is loaded on the unified architecture server and the address space is published to obtain the effective address space. Based on the effective address space, a one-to-one correspondence is established between the node identifier and the port name in the port dictionary, and the binding table from port to node is output.

4. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 3, characterized in that: The namespace version is obtained by numbering the node allocation table generated from the port dictionary using a preset version encoding rule and registering it as a namespace identifier.

5. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 4, characterized in that: The process of unifying control engineering variables based on the port dictionary driver specifically involves: Convert the port dictionary into a control engineering variable table while keeping the port names consistent with the variable names to obtain a variable consistency list; The variable uniformity list is divided into control output set and control input set according to direction and data type, resulting in a variable grouping table; Write the variable grouping table into the control project and complete the compilation and download to obtain the virtual controller project.

6. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 5, characterized in that: The unified architecture subscription and publication configuration based on the binding table is as follows: Organize the binding table into a list of subscription objects and label the variable nodes and event nodes corresponding to the control inputs to form the subscription configuration; Organize the binding table into a list of published objects and mark the variable nodes corresponding to the control output to form the published configuration; Load the subscription and publishing configurations into the joint debugging monitoring gateway and enable the session connection to obtain the joint debugging channel.

7. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 6, characterized in that: The formation of the event mirror volume and third-party version fingerprint is specifically as follows: The virtual controller project and simulation project package are connected through the joint debugging channel, and the actuator actions are triggered according to the process sequence table to obtain the virtual joint debugging operation state; The virtual joint debugging running state is used to synchronously collect address space variable change records and event node trigger records, and arrange them in chronological order to obtain an event sequence; The namespace version, virtual controller project version, and simulation project package version are used as version fingerprints and associated with the event sequence to form an event mirror volume and third-party version fingerprints.

8. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 7, characterized in that: The process of performing a consistency audit on the event mirror volume according to node type and process sequence table, and locating the deviation node, specifically involves: The event mirror volume is parsed into object-level event traces according to node type definition and the correspondence between variable nodes and event nodes is preserved to obtain the audit trace set; The audit trajectory set is checked against the sorting, sorting, and packing status progression order according to the process sequence table, and inconsistent sections are marked to obtain the deviation section table; The deviation segment table is associated with the binding table, and the specific object type, node identifier, and port identifier are located to obtain the deviation node list.

9. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 8, characterized in that: The obtained corrected node set file and project package are specifically as follows: The list of deviation nodes is broken down into control engineering correction items and simulation engineering correction items, which are respectively pointed to interlocking relationships, counting triggering relationships, motion holding relationships, actuator stroke, initial pose, sensor installation position, and sequence segment trigger point to obtain the correction task table. Update the virtual controller project and simulation project package according to the revised task list, and complete the recompiling and reloading to obtain the revised project package; Based on the revised project package, the namespace version is incremented and the node set file is regenerated to form the revised node set file and project package.

10. The method for three-dimensional simulation debugging and monitoring of automated production lines as described in claim 9, characterized in that: The formation of the monitoring and traceability database specifically includes: The revised node set file and project package are distributed to the field monitoring gateway and field controller, and the unified architecture address space is enabled to obtain the field version locked state. Based on the on-site version locked state continuous archive address space variable change records and event node trigger records, and divided into volumes according to the third-party version fingerprint, the on-site event archive volume is obtained; The on-site event archive triggers offline replay and links the simulation engineering package and virtual controller engineering to reproduce the process sequence, thus obtaining a reproduction diagnostic volume; The on-site event archive, the reproduction diagnostics archive, and the namespace version sequence are combined to form a monitoring and traceability library.

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