A semi-physical simulation system platform for fire-related assembly production line

Abstract

The utility model discloses a kind of semi-physical simulation system platform for fire-related assembly production line, comprising: simulation environment module, real object module and virtual-real interaction module;Wherein, the real object module is connected with host computer communication, the simulation environment module is connected with virtual-real interaction module by USB, the simulation environment module is directly connected with real object module communication by network cable, the virtual-real interaction module is installed on real object module.The utility model carries out real-time interaction of real object and simulation model by the semi-physical simulation system platform provided, and the real input-output response generated by real-time interaction is used to evaluate the control stability, effectiveness, accuracy and the like of control software, with the effect that operability is strong, and evaluation cost is controllable.

Description

Technical Field

[0001] This utility model relates to the field of fire-related industrial production. More specifically, this utility model relates to a hardware-in-the-loop simulation system platform for fire-related assembly production lines. Background Technology

[0002] In the automated production and assembly process of fire-related enterprises, the production process and production and assembly actions are automatically completed by the upper computer scheduling software and the lower-level control software. (It should be noted that the term "fire-related enterprise" here refers to an enterprise involved in the production and assembly of flammable and explosive hazardous materials (such as gunpowder, explosives, propellants, etc.). After the software control system is designed, a safety risk assessment test must be conducted on the control software; otherwise, if a problem occurs in the actual production and assembly process of fire-related products, the consequences will be very serious.)

[0003] While software designers can check and verify control software safety before program execution, they often struggle to identify their own errors and problems. Even if the program's syntax is correct, bugs are inevitable in its design logic. However, these bugs are usually well-hidden and difficult to detect during routine operation. Extensive, extreme, and diverse operational testing is typically required to uncover bugs or potential risks in the control software. Conducting such extensive, extreme, and diverse operational tests on production lines that are about to enter production or have already undergone trial production is impractical. It would not only consume significant time and effort but also pose risks of equipment instability or even uncontrollable situations for the user. Therefore, conducting a safety risk assessment of the control software before deploying it on automated production assembly lines for fire-related products is of paramount importance and is essential.

[0004] Given the urgent need to conduct safety risk assessments on the control software for automated production assembly lines of fire-related products, and considering the risks present during the commissioning of existing automated production lines (e.g., 1) control program logic errors may lead to dangerous collisions of actuators during the pressing process; 2) safety interlock logic defects may prevent the system from reliably shutting down when environmental limits are exceeded), it is necessary to develop a control software safety risk assessment system platform based on hardware-in-the-loop simulation to prevent the direct application of control software to the commissioning process of automated production lines.

[0005] Although in the existing technology, many industries have adopted hardware-in-the-loop simulation systems in product manufacturing, production line testing and other fields, such as the laminar flow cooling simulation system with patent application number 201520329816.9, the main purpose of the hardware-in-the-loop simulation system is to solve the technical problem that the test results obtained from laminar flow cooling in the existing technical solutions are not accurate, which in turn leads to inaccurate guidance on the control strategy of the hot-rolled strip cooling system after the finishing mill. For example, patent application number 201320057151.1 describes a DCS system experimental platform that utilizes hardware-in-the-loop (HIL) simulation technology for process control research. This platform allows researchers to fully understand and master the composition, functional structure, and specific development aspects of a DCS system. Furthermore, using a computer-generated production simulation model as the controlled object of the DCS system enables researchers to learn how to utilize a DCS system to achieve industrial process control.

[0006] For example, a semi-physical simulation device for coal-to-oil purification, patent application number 202420758398.4, mainly includes a shift conversion section, a low-temperature methanol washing section, and simulated materials. It can effectively represent the typical coal-to-oil purification process in industrial practice. This allows trainees to understand the typical process flow, production principle, structure, and performance of the main equipment in the shift conversion and low-temperature methanol washing processes. Additionally, patent application number 201220611088.7 describes a hardware-in-the-loop simulation system for testing the protection performance of DC circuit breakers on ships. This system comprises an elEGAsim real-time digital simulator, a current signal power amplifier, and the DC circuit breaker under test, forming a closed-loop simulation test platform. The primary circuit of the DC circuit breaker under test is connected to this closed-loop simulation test platform. This invention is applicable to the protection performance testing of shock-resistant DC circuit breakers without current transformers (CTs). It can accurately and efficiently detect or verify the trip current setting value and tripping time of the DC circuit breaker, as well as the operational coordination between system-level protection mechanisms.

[0007] Based on the aforementioned existing technologies, although hardware-in-the-loop simulation systems are used in various industries, a hardware-in-the-loop simulation system platform specifically for fire-related assembly lines is still under development and cannot meet the evaluation needs of existing fire-related assembly lines. Utility Model Content

[0008] One object of this invention is to solve the above-mentioned problems and / or defects, and to provide the advantages that will be described later.

[0009] To achieve these objectives and other advantages of this utility model, a semi-physical simulation system platform for fire-related assembly production lines is provided, comprising: a simulation environment module, a physical module, and a virtual-physical interaction module. The physical module is connected to the host computer for communication, the simulation environment module is connected to the virtual-physical interaction module via USB, the simulation environment module is directly connected to the physical module via a network cable, and the virtual-physical interaction module is installed on the physical module.

[0010] Preferably, the simulation environment module includes: a digital model of the assembly equipment, a simulation controller, and a communication module for interconnecting the equipment; The physical modules include: a host computer, a PLC controller, proximity switches, and motors used in the actual production process; The virtual-real interaction module includes: A sensor installed on a motor to obtain the motor's rotation angle; A trigger mounted on a proximity switch to transmit signals from a simulated environment to a physical module.

[0011] Preferably, the digital model includes: two six-axis industrial robots mounted on a slide rail, a laser tracker, and a six-degree-of-freedom platform set between the six-axis industrial robots.

[0012] Preferably, the simulation controller includes: Controller I, which works in conjunction with each set of six-axis industrial robots; Controller II, designed to work with a six-degree-of-freedom platform; Controller III, which works in conjunction with the laser tracker.

[0013] Preferably, the device communication module includes: Submodule I, which enables communication and interconnection between the controllers and the physical modules; Submodule II enables communication between the controllers.

[0014] This invention offers at least the following advantages: It simulates the realism of the system testing process by physically representing the computer, PLC, and other controllers equipped with control software, as well as small actuators such as motors, into physical modules. It also simulates the controlled object, such as a robotic arm or a production line, into a simulation environment module. The physical modules and the simulation environment module communicate and interconnect through a virtual-physical interaction module, thus establishing a testing system platform for the safety risk assessment of control software based on a semi-physical, semi-simulation approach. Evaluation experts can use the semi-physical simulation system platform provided by this solution to perform real-time interaction between the physical and simulation models. Through the realistic input and output responses generated by this real-time interaction, they can evaluate the control software's stability, effectiveness, and accuracy. Experiments and applications have proven that the system platform provided by this solution offers higher reliability in evaluation results compared to directly applying the control software to an actual production line, making it a safe and reliable hybrid testing method.

[0015] Other advantages, objectives and features of this invention will be partly apparent from the following description, and partly understood by those skilled in the art through study and practice of this invention. Attached Figure Description

[0016] Figure 1 This is a system block diagram of a semi-physical simulation system platform for fire-related assembly production lines in this utility model; Figure 2 This is a block diagram illustrating the connection principle of the hardware-in-the-loop simulation system platform in this utility model. Figure 3 This is a schematic diagram of the layout of the digital model in this utility model. Detailed Implementation

[0017] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0018] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0019] It should be noted that in the description of this utility model, the terms indicating orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. In addition, the terms "I" and "II" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "installed", "equipped with", "sleeved / connected", "connected", etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0021] Furthermore, in this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Moreover, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0022] Example 1 A hardware-in-the-loop simulation system platform for fire-related assembly lines, its structure is as follows: Figure 1-3As shown, it includes: simulation environment module 1, physical module 2 and virtual-physical interaction module 3. In actual application, simulation environment module 1 directly communicates with physical module 2 to exchange some information. At the same time, it interacts with physical module 2 through virtual-physical interaction module 3. Finally, physical module 2 can directly control the virtual assembly line in simulation environment module 1 to assemble equipment, thereby simulating the real operation scenario of assembly work. The simulation environment module 1 is connected to the virtual-real interaction module 3 via USB, receives some motion information, and can feed back signals generated in the simulation system. The simulation environment module 1 is also directly connected to the physical module 2 via a network cable to communicate with the host computer 20 in the physical module 2, thereby enabling the physical module 2 to directly control the virtual devices in the simulation system.

[0023] The simulation environment module 1 includes: a digital model 10 of the assembled equipment, a simulation controller (not shown), and a communication module (not shown) for interconnecting the equipment.

[0024] like Figure 3 As shown, the digital model includes: two six-axis industrial robots 101 (the six-axis robots receive motion commands from the host computer 20 and display their motion status in real time in the simulation environment), which are respectively installed on the relatively arranged slide rails I 102; a six-degree-of-freedom platform 103 (the six-degree-of-freedom platform is a heavy-duty robot) is set between the slide rails I 102; a laser scanner 105 is set on the slide rail II 104 (the laser scanner receives motion commands sent by the host computer 20 and can move the laser scanner back and forth); and corresponding elevators (not shown) are set on the left and right sides of the six-degree-of-freedom platform (receive commands sent by the keyboard of the simulation environment module 1; pressing q raises the left elevator and pressing a lowers it; pressing w raises the right elevator and pressing s lowers it).

[0025] The simulation controller includes: Controller I, which works with each set of six-axis industrial robots (Controller I controls the operation of the robotic arm's motor 23, receives external control data, processes collision detection and connector operations, and outputs a log file for recording); Controller II, which works with the six-degree-of-freedom platform (Controller II can communicate directly with the control software in the host computer 20, controls the movement of the six-degree-of-freedom platform in the simulation environment according to the communication protocol, and provides feedback on the coordinates of the actuators on the heavy-duty robot; Controller II performs inverse kinematics calculation of the six-degree-of-freedom platform (stewart) according to the control instructions of the host computer 20, calculates the extension and retraction lengths of the six electric cylinders, and displays the platform's motion state in real time in the simulation environment); Controller III, which works with the laser tracker (Controller III drives the linear motor of the laser scanner and detects touch events, receives external commands to set the motor position, and outputs a log file for recording); and Controller IV, which works with other fixed objects (Controller IV implements the collision detection function of fixed objects in the simulation environment, triggers collision events, and sends them to the collision server via TCP for collision event recording). The device communication module includes: a sub-module for communication with the simulation controller (the communication implementation module of the six-degree-of-freedom platform serves as the background processing loop of the platform task, responsible for establishing a TCP connection with the workstation (127.0.0.1:8990), receiving control commands, and replying with data or status after processing according to the protocol, depending on the platform6d class; the communication implementation module of the laser scanner serves as the task entry point of the laser measurement / positioning device, responsible for establishing a TCP connection with the host computer 20, receiving commands, and replying with position or status data according to the protocol), an OPCUA server read / write communication module, and a virtual-real interaction communication module.

[0026] The physical module 2 includes: a host computer 20, a PLC controller 21, a proximity switch 22, and a motor 23 used in the actual production process, wherein the host computer 20 is equipped with control software to be evaluated. The virtual-real interaction module 3 is installed at the end of the physical module 2 (here, the end refers to the mechanism at the very end of the control layer designed in layers, such as a motor, that performs the corresponding action). It is used to receive motion information generated by the motor 23 in the physical module and to feed back the signal generated by the simulation environment module 1 to the limit switch in the physical module. The virtual-real interaction module 3 includes: A sensor 30 is installed on the motor 23 to obtain the rotation angle of the motor 23; A trigger 31, mounted on proximity switch 22, is used to transmit signals from the simulation environment to the physical module.

[0027] The physical module is communicatively connected to the host computer 20, the simulation environment module 1 is connected to the virtual-physical interaction module 3 via USB, and the simulation environment module 1 is directly communicatively connected to the physical module via a network cable to communicate with the host computer 20 in the physical module, thereby enabling the physical module to directly control the virtual devices in the simulation system.

[0028] Working Principle: The host computer control software in the physical module serves as the actual control software used on the production line, outputting instructions to control the entire production line's process and equipment. In practical applications, the host computer control software sends control signals to the PLC controller and receives feedback data from the PLC controller. The PLC controller is connected to the motor and proximity switches using industry-standard connection methods. When the host computer control software drives the production equipment, the PLC controller drives the motor to rotate, which in turn drives the connected angle sensor (part of the virtual-physical interaction module) to move. The angle sensor receives angle information and transmits it to the simulation environment module via serial communication, thereby driving the corresponding equipment in the simulation environment. When the equipment in the simulation environment triggers a virtual proximity switch, the simulation environment sends a command to the trigger (part of the virtual-physical interaction module) via serial communication, triggering the corresponding physical proximity switch. The proximity switch sends trigger data to the PLC controller, which then feeds the signal back to the host computer software, thus achieving closed-loop control. Simultaneously, the host computer software and the various devices in the simulation environment module interact with each other via TCP and the OPCUA server. The host computer control software sends communication commands via TCP to control the motion of a virtual six-degree-of-freedom platform in the simulation environment. Simultaneously, the simulation environment feeds back motion status to the host computer software via TCP, forming a closed-loop control system. The host computer control software controls the six-axis industrial robot's motion through an OPCUA server, and the controller in the simulation environment reads the motion commands from the OPCUA server, enabling the six-axis industrial robot to perform virtual production tasks.

[0029] The hardware-in-the-loop simulation system platform of this solution is mainly responsible for the motion control of each robot in the simulation environment, as well as the fault detection function. The system can receive motion parameters sent from the server and display the motion status of each robot in the simulation environment in real time.

[0030] The hardware-in-the-loop (HIL) simulation system platform uses the original host computer control software of the production line to construct physical modules from the host computer and some physical components in the production line. A six-axis industrial robot, a six-degree-of-freedom platform, and a laser tracker are virtualized as the core simulation controller carrier, i.e., the simulation environment module, representing valuable equipment. Furthermore, through a virtual-physical interaction module, the robot, controller, and physical modules in the simulation environment are directly and indirectly organically integrated. The host computer's control commands are displayed in the simulation environment (e.g., by incorporating the inverse kinematics calculation function of a heavy-duty robot within the simulation environment module, the motion of a real heavy-duty robot can be simulated without modifying the commands sent by the host computer). This enables process testing during the overall assembly process, allowing for complete production simulation of the assembly line at minimal cost. Furthermore, because the simulation environment is easily reconfigurable and the host computer can receive real-time input and output from the physical components during operation, this solution can address the potential equipment damage during the debugging of automated assembly lines, reducing equipment debugging costs.

[0031] The above solutions are merely illustrative examples of preferred embodiments, but are not limited thereto. When implementing this invention, appropriate substitutions and / or modifications can be made according to the user's needs.

[0032] The number of devices and processing scale described herein are for the purpose of simplifying the description of this utility model. Applications, modifications, and variations of this utility model will be readily apparent to those skilled in the art.

[0033] Although embodiments of this utility model have been disclosed above, they are not limited to the applications listed in the specification and embodiments. It can be applied to various fields suitable for this utility model. Other modifications can be readily implemented by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, this utility model is not limited to the specific details and examples shown and described herein.

Claims

1. A hardware-in-the-loop simulation system platform for fire-related assembly production lines, characterized in that, include: Simulation environment module, physical object module, and virtual-physical interaction module; The physical module is connected to the host computer for communication, the simulation environment module is connected to the virtual-physical interaction module via USB, the simulation environment module is directly connected to the physical module via a network cable, and the virtual-physical interaction module is installed on the physical module.

2. The hardware-in-the-loop simulation system platform for fire-related assembly production lines as described in claim 1, characterized in that, The simulation environment module includes: a digital model of the assembled equipment, a simulation controller, and a communication module that enables communication and interconnection between the equipment; The physical modules include: a host computer, a PLC controller, proximity switches, and motors used in the actual production process; The virtual-real interaction module includes: A sensor installed on a motor to obtain the motor's rotation angle; A trigger mounted on a proximity switch to transmit signals from a simulated environment to a physical module.

3. The hardware-in-the-loop simulation system platform for fire-related assembly production lines as described in claim 2, characterized in that, The digital model includes: two six-axis industrial robots mounted on slide rails, a laser tracker, and a six-degree-of-freedom platform set between the six-axis industrial robots.

4. The hardware-in-the-loop simulation system platform for fire-related assembly production lines as described in claim 3, characterized in that, The simulation controller includes: Controller I, which works in conjunction with each set of six-axis industrial robots; Controller II, designed to work with a six-degree-of-freedom platform; Controller III, which works in conjunction with the laser tracker.

5. The hardware-in-the-loop simulation system platform for fire-related assembly production lines as described in claim 4, characterized in that, The communication module is: sub-module I, which enables communication interconnection between each controller and the physical module; Submodule II enables communication between the controllers.

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