Simulation verification method and system of flexible direct-drive maglev line
By constructing a virtual model and simulation verification method for flexible direct-drive maglev lines, the problems of high development cost, high risk, and long verification cycle in existing technologies have been solved. Early comprehensive algorithm performance testing and process logic integration testing have been achieved, a high-fidelity testing environment has been provided, and full-chain closed-loop testing has been supported, improving the efficiency and depth of R&D and debugging.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- KUNSHAN CHINANOO PRECISION TECH CO LTD
- Filing Date
- 2026-02-03
- Publication Date
- 2026-06-02
AI Technical Summary
The development and commissioning of existing flexible direct-drive maglev lines suffer from problems such as high development costs, high risks, long verification cycles, low efficiency, limited testing scenarios, incomplete coverage, and black-box process data. In particular, it is difficult to conduct systematic integration verification and in-depth analysis in the early stages of development.
A virtual model of a flexible direct-drive maglev line is constructed. A high-fidelity motor mathematical model and motion control algorithm are loaded through the FRT controller simulation module. The system receives instructions from the external process controller, generates dynamic response data of the virtual mover, and feeds it back to the external process controller in real time. It supports multiple industrial communication protocols and abnormal working condition simulation, and realizes full-process data transparency.
It enables early algorithm performance testing and process logic integration, shortens the development cycle by 40%-60%, reduces the risk of hardware damage, provides a high-fidelity testing environment, supports full-chain closed-loop testing, and improves the efficiency and depth of R&D and debugging.
Smart Images
Figure CN122131627A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of simulation technology for flexible direct-drive maglev lines, and in particular to simulation verification methods and systems for flexible direct-drive maglev lines. Background Technology
[0002] In flexible manufacturing systems, flexible direct-drive magnetic levitation lines (FRTs) are widely used due to their high precision and flexibility. However, the development of their core control algorithms and the debugging of the entire production line heavily rely on joint testing of the physical motor and the line itself. This testing method has the following problems: High development costs and risks: Algorithm testing directly affects expensive equipment, and improper operation can easily lead to equipment damage. Furthermore, the testing cycle is constrained by hardware availability.
[0003] Long verification cycle and low efficiency: The development of control algorithms and the development of upper-level process logic are often carried out in sequence, making it impossible to conduct systematic integration and verification in the early stages of development. Problems are discovered late, leading to project delays.
[0004] The testing scenarios are limited and incomplete: it is difficult to safely and conveniently simulate extreme working conditions (such as overload, emergency stop, communication failure) and complex multi-device collaborative scenarios, resulting in insufficient verification of system robustness.
[0005] Process data black boxing: During physical debugging, incomplete acquisition of internal state data is not conducive to in-depth analysis and optimization of algorithm performance.
[0006] Existing simulation technologies mostly focus on pure software-level motor model simulation or simple logic simulation, lacking deep and real-time collaboration with real industrial controllers (such as PLCs), and cannot truly reflect the interaction and coupling relationship between "control algorithm - drive system - process logic" in actual operation. Summary of the Invention
[0007] Based on this, a simulation verification method for flexible direct-drive magnetic levitation lines is provided. This method completely separates the physical motor and the line, allowing for comprehensive algorithm performance testing and process logic integration during the control program development phase, significantly shortening the development cycle.
[0008] To achieve the above objectives, the present invention adopts the following technical solution: A simulation verification method for a flexible direct-drive maglev line includes: Construct a virtual model of a flexible direct-drive maglev line. The FRT controller simulation module loads the virtual model and runs a high-fidelity motor mathematical model and motion control algorithm. The FRT controller simulation module receives control commands from an external process controller and performs real-time calculations based on the virtual model to generate dynamic response data for the virtual actuator. The dynamic response data is fed back to the external process controller in real time.
[0009] In one embodiment, the virtual model includes motors and their quantity, actuators and their quantity, workstations and their quantity, physical layout, control parameters, and communication network topology.
[0010] In one embodiment, The control commands of the external process controller include: target position, speed curve, and start / stop command. The dynamic response data of the virtual actuator includes real-time position, speed, and fault status.
[0011] In one embodiment, the external process controller runs the control program of the actual production line and issues control commands to the FRT controller simulation module according to the production process flow.
[0012] In one embodiment, the FRT controller simulation module supports interfacing with various industrial real-time communication protocols.
[0013] In one embodiment, various abnormal operating conditions are simulated during the simulation process.
[0014] In one embodiment, the dynamic response data is fed back to the human-computer interaction interface of the host computer in real time for visual monitoring.
[0015] In one embodiment, the host computer's human-computer interaction interface includes an interface for recording and replaying all data of the simulation process, an interface for statistical analysis of performance indicators, an interface for exporting simulation data, and an interface for generating test reports or comparing them with theoretical design data.
[0016] A simulation verification system for a flexible direct-drive maglev line includes: The FRT controller simulation module includes an embedded motor model library, control algorithm library, and communication protocol stack. It receives external commands, drives the virtual model of the flexible direct-drive maglev line, and outputs simulation results. External process controller: Runs the actual production line control logic and interacts with the FRT controller simulation module in real time through an industrial communication interface. Data communication bus: connects the above modules.
[0017] In one embodiment, it also includes a host computer human-computer interaction module: used to provide a configuration interface for the virtual model, visual monitoring of the simulation process, historical data management, and simulation task management.
[0018] The beneficial effects of this application are as follows: 1. Achieve "software and hardware decoupling and early verification": Completely separate from physical motors and production lines, comprehensive algorithm performance testing and process logic integration can be carried out during the control program development stage, which greatly shortens the development cycle (reducing on-site debugging time by 40%-60%) and reduces the risk and cost of hardware damage caused by debugging errors.
[0019] 2. Supports integrated verification of "algorithm-process": It breaks down the barriers between control algorithm verification and production line PLC program verification in traditional simulation, and realizes closed-loop testing of the entire chain from upper-level process logic to lower-level drive control on a single platform, which can detect interaction problems at the system integration level earlier.
[0020] 3. Provides a high-fidelity and highly flexible testing environment: Through high-precision motor models and realistic industrial communication protocols, the simulation environment closely approximates the real physical system. Furthermore, various normal and abnormal test cases can be easily configured and reproduced, with test coverage far exceeding that of physical testing.
[0021] 4. Achieve full-process data transparency and traceability: All internal states, intermediate variables and control commands during the simulation process can be recorded, displayed and analyzed, providing strong data support for the optimization of control algorithms and fault diagnosis, and greatly improving the depth and efficiency of R&D and debugging. Attached Figure Description
[0022] Figure 1 This is a flowchart illustrating the simulation verification method for a flexible direct-drive maglev line according to an embodiment of this application.
[0023] Figure 2 This is a schematic diagram showing the connection between the FRT controller simulation module and other modules in an embodiment of this application.
[0024] Figure 3 This is a schematic diagram of the FRT virtual model configuration interface for an embodiment of this application.
[0025] Figure 4 This is a flowchart of the simulation verification process for this application.
[0026] Figure 5 This is a monitoring diagram of the actuator's operation process. Detailed Implementation
[0027] 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.
[0028] like Figure 1As shown, embodiments of this application provide a simulation verification method for a flexible direct-drive maglev line. The method includes: constructing a virtual model of the flexible direct-drive maglev line; loading the virtual model and running a high-fidelity motor mathematical model library and motion control algorithm library in an FRT controller simulation module; receiving control commands from an external process controller in an FRT controller simulation module; performing real-time calculations based on the virtual model to generate dynamic response data of a virtual mover; and feeding back the dynamic response data to the external process controller in real time.
[0029] Specifically, the aforementioned high-fidelity motor mathematical model library and motion control algorithm library can be implemented using existing technologies.
[0030] Specifically, the virtual model for constructing the flexible direct-drive maglev line includes: configuring the virtual model of the flexible direct-drive maglev line in a graphical or parametric manner through a host computer human-computer interaction interface developed based on the QT framework. The virtual model includes motors and their quantity, movers and their quantity, workstations and their quantity, physical layout, control parameters, and communication network topology.
[0031] Specifically, the control commands of the external process controller include: target position of the mover, speed curve of the mover, and start / stop command of the mover. The dynamic response data of the virtual mover includes real-time position, speed, and fault status.
[0032] Specifically, the aforementioned external process controller is either a real PLC or a software-simulated PLC.
[0033] In one embodiment, the external process controller runs the control program (ladder diagram, structured text, etc.) of the actual production line, sends control commands to the FRT controller simulation module according to the production process flow, and receives virtual motor status signals fed back by the FRT controller simulation module, thereby forming a complete closed-loop simulation test environment that includes "process logic - control algorithm - virtual controlled object".
[0034] In one embodiment, the FRT controller simulation module supports interface with various industrial real-time communication protocols, such as EtherCAT, TCP, and Modbus, ensuring that the communication timing and data format with the external PLC are consistent with the real hardware environment.
[0035] In one embodiment, various abnormal operating conditions are simulated during the simulation process.
[0036] Specifically, the simulation verification method for flexible direct-drive maglev lines in this application supports the introduction of interference models and fault injection functions. During the simulation process, various abnormal operating conditions such as network latency, packet loss, and encoder sensor failure can be simulated to test the fault tolerance and robustness of the control algorithm and process logic.
[0037] In one embodiment, such as Figure 2 and Figure 3 As shown, based on the above, the dynamic response data is fed back to the human-computer interaction interface of the host computer in real time for visual monitoring.
[0038] Specifically, the dynamic response data of the virtual actuators includes real-time position, velocity, and fault status. After the dynamic response data is fed back to the host computer, the human-machine interface on the host computer displays each virtual actuator in real time based on the above data, thus monitoring the status of each virtual actuator.
[0039] In one embodiment, the host computer's human-computer interaction interface is used for configuring the model and monitoring the simulation. It includes an interface for recording and replaying all simulation data, an interface for statistically analyzing performance indicators, an interface for exporting simulation data, and an interface for generating test reports or comparing them with theoretical design data. In other words, the host computer's human-computer interaction interface of this application has the following functions: recording and replaying all simulation data, performing statistical analysis of performance indicators, exporting simulation data, and generating test reports or comparing them with theoretical design data.
[0040] Another embodiment of this application provides a simulation verification system for a flexible direct-drive maglev line. The system includes: an FRT controller simulation module, which has an embedded motor model library, control algorithm library and communication protocol stack, used to receive external commands, drive the virtual model of the flexible direct-drive maglev line to run, and output simulation results; an external process controller, which runs the actual production line control logic and interacts with the FRT controller simulation module in real time through an industrial communication interface; and a data communication bus, which connects the above modules.
[0041] Based on the above, in one embodiment, it also includes a host computer human-computer interaction module: used to provide configuration interface for virtual model, visualization monitoring of simulation process, historical data management and simulation task management.
[0042] The simulation verification system for the flexible direct-drive maglev line described in this application is designed to implement the simulation verification method for the flexible direct-drive maglev line described in this application.
[0043] The following combination Figure 4 The simulation verification process of this application is described in detail.
[0044] The model is built and configured. Based on the current motor and the motor arrangement of the maglev line, the position information of the maglev line, motor information, encoder information, etc. are downloaded to the FRT controller simulation module.
[0045] Configure motion control parameters, including motion gain, motion feedforward, and motion filtering parameters.
[0046] Set the target position and start the mover to move to the target position.
[0047] Monitor the feedback from the FRT controller simulation module to determine whether the mover has reached the target position.
[0048] Once the mover reaches the target position, determine whether it should continue moving. If it should continue moving, repeat steps 3 and 4 above. If it should not continue moving, the movement stops and waits for the next trigger.
[0049] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.
Claims
1. A simulation verification method for a flexible direct-drive magnetic levitation line, characterized in that, include: Construct a virtual model of a flexible direct-drive maglev line. The FRT controller simulation module loads the virtual model and runs a high-fidelity motor mathematical model and motion control algorithm. The FRT controller simulation module receives control commands from an external process controller and performs real-time calculations based on the virtual model to generate dynamic response data for the virtual actuator. The dynamic response data is fed back to the external process controller in real time.
2. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The virtual model includes motors and their quantity, actuators and their quantity, workstations and their quantity, physical layout, control parameters, and communication network topology.
3. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The control commands of the external process controller include: target position, speed curve, and start / stop command. The dynamic response data of the virtual actuator includes real-time position, speed, and fault status.
4. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The external process controller runs the control program of the actual production line and sends control commands to the FRT controller simulation module according to the production process flow.
5. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The FRT controller simulation module supports integration with various industrial real-time communication protocols.
6. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The simulation process simulates various abnormal operating conditions.
7. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The dynamic response data is fed back to the host computer's human-computer interaction interface in real time for visual monitoring.
8. The simulation verification method for flexible direct-drive magnetic levitation lines according to claim 1, characterized in that, The host computer's human-computer interaction interface includes an interface for recording and replaying all simulation data, an interface for statistical analysis of performance indicators, an interface for exporting simulation data, and an interface for generating test reports or comparing them with theoretical design data.
9. A simulation verification system for a flexible direct-drive maglev line, characterized in that, include: The FRT controller simulation module includes an embedded motor model library, control algorithm library, and communication protocol stack. It receives external commands, drives the virtual model of the flexible direct-drive maglev line, and outputs simulation results. External process controller: Runs the actual production line control logic and interacts with the FRT controller simulation module in real time through an industrial communication interface. Data communication bus: connects the above modules.
10. The simulation verification system for flexible direct-drive maglev lines according to claim 9, characterized in that, It also includes a host computer human-computer interaction module: used to provide configuration interfaces for virtual models, visual monitoring of the simulation process, historical data management, and simulation task management.