Interface and method for transferring data between a processing station and a computer-aided simulation model

Abstract

A method for transferring data (DB1, DM1) between a processing station (1) and a computer-aided simulation model (2) of the processing station (1) using an interface (3) and a correspondingly configured interface (3) are proposed, wherein the interface (3) receives data (DB1) from the processing station (1), and wherein the interface (3) transmits the data (DB1) received from the processing station (1) to the computer-aided simulation model (2) of the processing station (1) and vice versa. In this way, direct communication between the physically existing processing station (1) and the virtual simulation is achieved.

Description

[0001] The invention relates to an interface and a method for transferring data between a processing station, in particular a roll forming station, and a computer-aided simulation model of the processing station.

[0002] Various software solutions for simulating manufacturing processes are known in the art, such as robot process simulations, thermoforming simulations, folding simulations, or adhesive application simulations. These simulations run on a computing unit, particularly a computer, and can help determine operating parameters for real robots or processing stations. The simulation results are read out by an operator, usually via a display device, and then manually transferred to the control unit of the robot or processing station. The operator can then observe the actual behavior of the robot or processing station and adjust the simulation parameters to better replicate its real-world behavior.

[0003] This process of comparing simulation data with real physical data is time-consuming and can be prone to errors.

[0004] Against this background, it is an object of the present invention to provide an improved transfer of data between a processing station and a computer-aided simulation model of the processing station, which is in particular less time-consuming and in particular less prone to errors.

[0005] To solve this problem, a method for transferring data between a processing station and a computer-aided simulation model of the processing station, as well as an interface according to the independent claims, are proposed. Further advantageous embodiments of the invention are described in the dependent claims and the description, and illustrated in the figures.

[0006] The proposed solution provides a method for transferring data between a processing station, in particular a roll forming station, and a computer simulation model of the processing station using an interface, in particular a bidirectional interface, wherein the interface receives data from the processing station and transmits the data received from the processing station to the computer simulation model of the processing station. The computer simulation model of the processing station is, in particular, a computer model in which the processing station is simulated in a simplified or highly simplified manner.In particular, the computer-aided simulation model of the machining station is intended to simulate only the machining process itself, specifically simulating the effects of the forces acting on a workpiece to be machined by the machining station. In one embodiment, the computer-aided simulation model of the machining station can thus be a computer-aided simulation model of the machining process itself. Advantageously, the computer-aided simulation model is a digital twin of the machining station, and it is specifically intended that process-relevant control variables of the machining station, acquired or acquirable by means of measuring sensors, are used and / or simulated 1:1 in the computer-aided simulation model.Advantageously, the interface establishes direct communication between the actual, physical machining station and the computer-aided simulation model. This eliminates the need for manual data transfer from the machining station to the computer-aided simulation model. The data from the machining station is acquired primarily during machining operations performed by the station. The data transferred to the computer-aided simulation model then allows for improved and faster parameterization of the model, enabling a more realistic simulation of the machining station and the machining operations it can perform.

[0007] It is particularly advantageous to embed the interface, especially the bidirectional interface, for efficient and direct communication between the respective process simulations within the control software of the machining station.

[0008] An advantageous embodiment of the method provides that the data received by the machining station includes sensor data from sensors assigned to the machining station for process monitoring. The interface advantageously transmits the received sensor data to the computer-aided simulation model of the machining station. In this way, an efficient feedback loop of information for representing the real-world conditions within the simulation is also advantageously established. The computer-aided simulation model can thus advantageously provide a further improved representation of the behavior of the machining station and / or the result of machining a workpiece using the machining station.

[0009] Advantageously, the interface, and in particular a conversion unit of the interface, transforms the data received from the machining station into data usable by the computer simulation model, specifically data directly usable by the computer simulation model, which the computer simulation model can then advantageously use to perform a simulation of a machining operation at the machining station. Specifically, the interface receives data from the machining station, converts this received data into data directly usable by the computer simulation model, and transmits the converted data to the computer simulation model. Advantageously, this eliminates the need for any or only minor adjustments to the computer simulation model to use the data provided by the interface.This also advantageously simplifies, in particular, the use of computer-aided simulation models from third-party providers with limited customization options.

[0010] Another advantageous embodiment of the method provides that the interface receives data from the computer-aided simulation model. The data received from the computer-aided simulation model advantageously includes control signals and / or parameter settings for simulated actuators of the machining station, as determined by the computer-aided simulation model. Advantageously, simulation results generated by the computer-aided simulation model can thus be made available for further use via the interface.

[0011] The interface is particularly advantageous because it transmits the data received from the computer-aided simulation model to the machining station or to an electronic control unit of the machining station. Insights gained through the computer-aided simulation model can thus be advantageously implemented directly by the actual machining station. This significantly accelerates the setup of a machining process, especially a machining process for the consistent processing of identical workpieces in large quantities.

[0012] Furthermore, the interface, and in particular a conversion unit of the interface, advantageously transforms the data received from the computer-aided simulation model into data usable by the processing station, in particular into data directly usable by the processing station, with which at least one actuator of the processing station can advantageously be controlled for a processing operation. In particular, it is provided that the interface receives data from the computer-aided simulation model, converts this received data into data directly usable by the processing station, and transmits the data thus converted to the processing station, in particular to an electronic control unit of the processing station.Advantageously, this method requires little to no modifications to the processing station or its electronic control unit to utilize the data provided by the interface. This also enables efficient and direct communication between the respective process simulations within the processing station's control software.

[0013] According to a further advantageous embodiment, the interface manipulates the data to be transmitted according to a configurable setting, whereby the manipulation specifically involves adding an offset and / or applying a scaling factor. The data manipulation can relate in particular to the data to be transmitted to the computer-aided simulation model and / or to the data to be transmitted to the machining station. Advantageously, these manipulations allow deviations between the behavior of the real machining station and the behavior of the computer-aided simulation model to be compensated for, advantageously without having to change the parameterization for the computer-aided simulation model, which can be particularly beneficial when using a computer-aided simulation model from a third-party manufacturer.Furthermore, such manipulations can often be implemented more easily and quickly via the interface than in the computer-aided simulation model. For example, if a comparison between a real folding process using the actual processing station and the corresponding process simulation using the computer-aided simulation model shows that the same results are achieved when the actual pressing force of the folding roller deviates from the simulated value by a certain value, such as 2 N (N: Newton), then a corresponding offset can be set using the interface when transferring the data between the actual processing station and the computer-aided simulation model. In the case of percentage deviations, a corresponding scaling factor can be set using the interface instead.Furthermore, it may be provided that the interface modifies the data to be transmitted for manipulation of a robot path, in particular for a predefinable manipulation of a robot path, especially according to adjustable specifications.

[0014] According to a further advantageous aspect, the computer-aided simulation model comprises a first computer-aided simulation submodel for simulating at least one actuator of the machining station, in particular for simulating a robot of the machining station, and a second computer-aided simulation submodel for simulating a machining process of the machining station. Advantageously, the interface receives data from the first computer-aided simulation submodel and data from the second computer-aided simulation submodel. In this configuration, the data received by the interface from the computer-aided simulation model is thus advantageously separated for improved provision to the machining station into data received from the first computer-aided simulation submodel and data received from the second computer-aided simulation submodel.In particular, additional computer-aided simulation submodels can be provided, from which the interface receives data. Furthermore, several primary computer-aided simulation submodels and / or several secondary computer-aided simulation submodels can be provided, from which the interface receives data. Advantageously, the interface allows the user to configure which data should be transmitted to the processing station. Specifically, the interface can also appropriately mark the data received from the computer-aided simulation submodels, particularly by manipulating a data header, so that the data can be correctly assigned and used by the processing station. This further reduces the occurrence of errors.

[0015] It is further advantageous that the interface transmits the data received from the first computer-based simulation submodel to the second computer-based simulation submodel. Furthermore, the interface advantageously transmits the data received from the second computer-based simulation submodel to the first computer-based simulation submodel. This also advantageously improves communication between the simulation submodels. In particular, interlocking simulation subroutines can be better coordinated, especially with minimal manual effort.

[0016] Advantageously, the interface, and in particular a conversion unit of the interface, converts the data received by the first computer-based simulation submodel into data usable by the second computer-based simulation submodel. Furthermore, the interface, and in particular a conversion unit of the interface, advantageously converts the data received by the second computer-based simulation submodel into data usable by the first computer-based simulation submodel. This further improves the exchange and use of the data generated by the respective simulation submodels.

[0017] The interface proposed for solving the aforementioned problem comprises inputs for receiving data and outputs for sending data, wherein at least one first input of the interface is configured to receive data from a processing station, in particular a roll forming station, and wherein at least one first output of the interface is configured to transmit the data received from the processing station to a computer-aided simulation model of the processing station, in particular a digital twin of the processing station. Here, too, the computer-aided simulation model of the processing station is in particular a computer-aided model in which the processing station is simulated in a simplified or highly simplified manner.In particular, it is intended that the computer-aided simulation model of the machining station only simulates the machining process itself, specifically simulating the effects of the forces acting on a workpiece to be machined by the machining station. In one embodiment, the computer-aided simulation model of the machining station can thus be a computer-aided simulation model of the machining process itself. If the computer-aided simulation model is a digital twin of the machining station, it is specifically intended that process-relevant control variables of the machining station, acquired or acquirable by means of measuring sensors, are used and / or simulated 1:1 in the computer-aided simulation model.

[0018] Advantageously, the proposed interface enables direct communication between the computer-aided simulation model and the actual physical machining station. Furthermore, the interface is advantageously embedded as a bidirectional interface for efficient and direct communication between the respective process simulations within the machining station's control software. In parallel, appropriate sensor technology can advantageously be used to capture the current state of process-relevant parameters during the execution of a machining operation by the machining station. In this way, an efficient feedback loop of information is advantageously possible for representing the real-world states within the computer-aided simulation model.

[0019] An advantageous embodiment of the interface provides that at least one second input of the interface is configured to receive data from the computer-aided simulation model, wherein the data includes, in particular, control signals for at least one actuator of the simulation model. Furthermore, at least one second output of the interface is advantageously configured to transmit the data received from the computer-aided simulation model to the machining station. This advantageously improves the provision of data generated during process simulation using the computer-aided simulation model to the machining station, thereby accelerating the setup of a machining process for serial part machining.

[0020] The interface is particularly advantageous for transferring data between a processing station and a computer-aided simulation model according to a method developed according to the invention. Advantageously, the interface allows the benefits of the proposed method to be realized.

[0021] According to a further advantageous embodiment, the interface comprises a conversion unit, wherein the conversion unit is advantageously configured to convert data received from the processing station into data usable for a simulation by the computer-aided simulation model, in particular directly usable data, and / or to convert data received from the computer-aided simulation model into data usable by the processing station, in particular directly usable data. Advantageously, the conversion unit is further configured to convert the data received from the computer-aided simulation model into control signals for controlling at least one actuator of the processing station.

[0022] A further advantageous embodiment provides that the computer-aided simulation model comprises a first computer-aided simulation submodel for simulating at least one actuator of the machining station, in particular for simulating at least one robot of the machining station, and a second computer-aided simulation submodel for simulating a machining process of the machining station, wherein at least a third input of the interface is configured to receive data from the first computer-aided simulation submodel, and at least a fourth input of the interface is configured to receive data from the second computer-aided simulation submodel. In particular, at least a third output is configured to transmit the data received from the first computer-aided simulation submodel to the second computer-aided simulation submodel.Advantageously, at least a fourth output is provided to transfer the data received from the second computer-based simulation submodel to the first computer-based simulation submodel. This further improves the exchange of simulation data between simulation submodels of the computer-based simulation model.

[0023] Further advantageous details, features and embodiments of the invention are explained in more detail in connection with the exemplary embodiments shown in the figures (Fig.: Figure). These show: Fig. 1 in a block diagram representation an embodiment of an interface designed according to the invention for carrying out a method designed according to the invention.

[0024] In Fig. Figure 1 is an embodiment of an interface 3 with inputs 331, 332, 333, 334, 335 for receiving data DB1, DM1, DBS1, DMS21, DMS22 and outputs 341, 342, 343, 344, 345 for outputting data DB1 (DB1'), DM1 (DM1'), DBS1 (DBS1'), DMS21 (DMS21'), DMS22 (DMS22'). The interface 3 is designed for transmitting data between a processing station 1, which may in particular be a roll forming station for the serial folding of body components of motor vehicles, and a computer-aided simulation model 2, wherein the computer-aided simulation model 2 is in particular a digital twin of the processing station 1.

[0025] The computer-aided simulation model 2 is designed to simulate machining operations to be carried out by means of the machining station 1, whereby the results of the simulation can be used in particular to adjust a machining process for processing a plurality of identical component arrangements, in the case of a roll folding station a roll folding process for folding a plurality of identical component arrangements, more quickly.

[0026] In this embodiment, a plurality of sensors 4 are assigned to processing station 1, which are designed to monitor a processing operation actually performed by processing station 1. If processing station 1 is a roll folding station, the roll folding station is specifically assigned sensors for monitoring the contact force of the folding roller, for monitoring the movement of the folding robot, and / or for monitoring the fold quality with respect to the folded component arrangement. The double arrow shown with a dashed line between block 1 and block 4 indicates this. Fig. 1 symbolically represents the assignment between the majority of the sensors 4 and the processing station 1, whereby the processing station 1 uses the data recorded by the sensors 4 in particular also for controlling the actuators 5.

[0027] In this embodiment, the computer-aided simulation model 2, with which the machining operations executable by the machining station 1 can be virtually simulated, is assigned a first computer-aided simulation submodel 21 and a second computer-aided simulation submodel 22. The assignment is shown in Fig. 1 is symbolically represented by the respective dashed double arrow between block 2 and block 21 or between block 2 and block 22. In this embodiment, the first computer-aided simulation submodel 21 can simulate the actuators 5 of the processing station 1, in the case of a roll folding station, in particular a folding robot. Specifically, the first computer-aided simulation submodel 21 can include robot simulation software. In this embodiment, the second computer-aided simulation submodel 22 is designed to simulate the processing processes of the processing station 1, in the case of a roll folding station, in particular various roll folding operations. Specifically, the second computer-aided simulation submodel 22 can include process simulation software.The first computer-aided simulation submodel 21 and the second computer-aided simulation submodel 22 may in particular originate from different providers and are not necessarily coordinated with each other.

[0028] Interface 3 establishes direct communication between the computer-aided virtual simulation model 2, including its associated simulation submodels 21 and 22, and the processing station 1, including its associated sensors 4. Advantageously, this interface 3 integrates a bidirectional "post-processing" interface for efficient and direct communication between the respective process simulations within the control software of processing station 1. Simultaneously, sensor data from the sensor technology is transmitted to the computer-aided simulation model 2 to capture the current state of the process-relevant parameters of processing station 1. This enables an efficient feedback loop for representing the real-world states of processing station 1 within the simulation of the computer-aided simulation model 2.

[0029] Interface 3 includes a first input 331, configured to receive data DB1 from processing station 1. This data can be, in particular, control data used to actuate actuators 5 of processing station 1. Interface 3 also includes a second input 332, configured to receive data DM1 from the computer-aided simulation model 2. This data DM1 can be, in particular, control data used to actuate simulated actuators of processing station 1. Furthermore, interface 3 includes a third input 333, configured to receive sensor data DBS1 from the sensors 4 assigned to processing station 1. Finally, interface 3 includes a fourth input 334, configured to receive data DMS21 from the first computer-aided simulation submodel 21.This data DMS21 relates in particular to the simulation of the actuators 5 of processing station 1. Furthermore, interface 3 has a fifth input 335, which is configured to receive data DMS22 from the second computer-aided simulation submodel 22. This data DMS22 relates in particular to the simulation of the machining process of processing station 1.

[0030] Furthermore, interface 3 includes various outputs for providing the received data. In this embodiment, interface 3 includes a first output 341, which is configured to transmit data, in particular the data DB1 received from processing station 1, to the computer-aided simulation model 2. A second output 342 of interface 3 is configured to transmit data, in particular the data DM1 received from the computer-aided simulation model 2, to processing station 1. Interface 3 also includes a third output 343, which is configured to transmit data, in particular the sensor data DBS1 received from sensors 4, to the computer-aided simulation model 2. Two further outputs 344, 345 of interface 3 are configured in this embodiment to provide data to the respective computer-aided simulation submodels 21, 22.

[0031] Using interface 3, data DB1, DBS1, DM1 can now be transferred between the processing station 1 and the computer-aided simulation model 2, whereby interface 3 makes the data DB1, DBS1, DM1, DMS21, DMS22 received via inputs 331, 332, 333, 334, 335 available for transmission at outputs 341, 342, 343, 344, 345.

[0032] The data DB1, DBS1, DM1, DMS21, DMS22 received by interface 3 can be made available by interface 3 to the various units 1, 2, 21, 22 via outputs 341, 342, 343, 344, 345 of interface 3 in converted and / or further processed form as data DB1', DBS1', DM1', DMS21', DMS22'. Interface 3 can therefore be configured to process the received data DB1, DBS1, DM1, DMS21, DMS22. In this embodiment, interface 3 includes a conversion unit 31, which allows data from the providing unit to be adapted to the format or data specifications of the receiving unit.Specifically, interface 3 converts the data DB1 received from processing station 1 into data DB1' usable by the computer-aided simulation model 2, which the computer-aided simulation model 2 can use to, in particular, simulate a processing operation of processing station 1. Furthermore, interface 3 can convert the data DM1 received from the computer-aided simulation model 2 into data DM1' usable by processing station 1 using conversion unit 31, which can be used to control the actuators 5 of processing station 1 for a processing operation.Furthermore, the conversion unit 31 of interface 3 can convert the data DMS21 received from the first computer-aided simulation submodel 21 into data DMS21' usable for the second computer-aided simulation submodel 22 and convert the data DMS22 received from the second computer-aided simulation submodel 22 into data DMS22' usable for the first computer-aided simulation submodel 21.

[0033] In the Fig. In the embodiment shown in Figure 1, interface 3 also includes a manipulator unit 32 with which the received data DB1, DBS1, DM1, DMS21, DMS22 can be modified, in particular according to configurable specifications. In this embodiment, it is provided that an offset can be added to values ​​of received data by means of the manipulator unit 32 and / or values ​​of received data can be multiplied by a predefinable scaling factor. Advantageously, interface 3 includes a manipulator unit 32 that can be configured to function as a control unit. Fig. 1. Input / output interface (not shown) with which a user can make the corresponding settings and configurations of interface 3.

[0034] For the application of interface 3, it is specifically intended that interface 3 receives data DB1 from processing station 1 and transmits the data DB1 received from processing station 1 to the computer-aided simulation model 2. The data received from processing station 1 includes sensor data DBS1 from sensors 4, which is also transmitted by interface 3 to the computer-aided simulation model 2. Furthermore, interface 3 receives data DM1 from the computer-aided simulation model 2, and the data DM1 received from the computer-aided simulation model 2 is transmitted to processing station 1.

[0035] Furthermore, interface 3 receives data DMS21 from the first computer-aided simulation submodel 21 and data DMS22 from the second computer-aided simulation submodel 22, wherein interface 3 transmits the data DMS21 received from the first computer-aided simulation submodel 21 to the second computer-aided simulation submodel 22, and transmits the data DMS22 received from the second computer-aided simulation submodel 22 to the first computer-aided simulation submodel 21.

[0036] In this way, direct communication is established between processing station 1 and the computer-aided simulation model 2 of the processing station, and direct communication is also enabled for simulation submodels 21 and 22 integrated into simulation model 2 for robot and process simulation, respectively. In particular, this allows different solutions available on the market for simulating manufacturing processes, especially robot process simulation, folding simulation, and / or adhesive application simulation, to be linked together.

[0037] The embodiments shown in the figures and explained in connection with them serve to illustrate the invention and are not limiting to it. Reference symbol list 1 processing station 2 computer-aided simulation model 21 first computer-aided simulation submodel 22 second computer-aided simulation submodel 3 Interface 31 Conversion unit of the interface (3) 32 Interface manipulator unit (3) 331 Interface input (3) 332 Interface input (3) 333 Interface input (3) 334 Interface input (3) 335 Interface input (3) 341 Interface output (3) 342 Interface output (3) 343 Interface output (3) 344 Interface output (3) 345 Interface output (3) 4 Sensor 5 Actuator of the processing station (1) DB1 Data from the processing station (1) DBS1 sensor data DB1' converted data of the processing station (1) DBS1' converted sensor data DM1 data from the computer-aided simulation model (2) DM1' converted data of the computer-aided simulation model (2) DMC1 control signals DMS21 data from the first computer-aided simulation submodel (21) DMS22 data from the second computer-aided simulation submodel (22) DMS21' converted data from the first computer-aided simulation submodel (21) DMS22' converted data from the second computer-aided simulation submodel (22)

Claims

[1] Method for transferring data (DB1, DM1) between a processing station (1) and a computer simulation model (2) of the processing station (1) using an interface (3), wherein the interface (3) receives data (DB1) from the processing station (1), and wherein the interface (3) transmits the data (DB1) received from the processing station (1) to the computer simulation model (2) of the processing station (1). [2] Method according to claim 1, characterized by , that the computer-aided simulation model (2) is a digital twin of the processing station (1). [3] Method according to claim 1 or claim 2, characterized by, that the data (DB1) received by the processing station (1) includes sensor data (DBS1) from sensors (4) assigned to the processing station (1) for process monitoring, wherein the interface (3) transmits the received sensor data (DBS1) to the computer simulation model (2). [4] Method according to any of the preceding claims, characterized by , that the interface (3) converts the data (DB1) received from the processing station (1) into data (DB1') usable for the computer-aided simulation model (2), with which the computer-aided simulation model (2) can perform a simulation of a processing operation of the processing station (1). [5] Method according to any of the foregoing claims, characterized by , that the interface (3) receives data (DM1) from the computer-aided simulation model (2). [6] Method according to claim 5, characterized by, that the data (DM1) received by the computer-aided simulation model (2) include control signals (DMC1) determined by the computer-aided simulation model (2) for at least one simulated actuator of the processing station (1). [7] Method according to claim 5 or claim 6, characterized by , that the interface (3) converts the data (DM1) received from the computer-aided simulation model (2) into data (DM1') usable for the processing station (1), with which at least one actuator (5) of the processing station (1) can be controlled for a processing operation. [8] Method according to any one of claims 5 to 7, characterized by , that the interface (3) transmits the data (DM1) received from the computer-aided simulation model (2) to the processing station (1). [9] Method according to any of the foregoing claims, characterized by, that the computer-aided simulation model (2) comprises a first computer-aided simulation submodel (21) for simulating at least one actuator (5) of the machining station (1) and a second computer-aided simulation submodel (22) for simulating a machining process of the machining station (1), wherein the interface (3) receives data (DMS21) from the first computer-aided simulation submodel (21) and receives data (DMS22) from the second computer-aided simulation submodel (22). [10] Method according to claim 9, characterized by , that the interface (3) converts the data (DMS21) received by the first computer-aided simulation submodel (21) into data (DMS21') usable by the second computer-aided simulation submodel (22), and / or converts the data (DMS22) received by the second computer-aided simulation submodel (22) into data (DMS22') usable by the first computer-aided simulation submodel (21). [11] Method according to any of the foregoing claims, characterized by , that the interface (3) transmits the data (DMS21) received from the first computer-aided simulation submodel (21) to the second computer-aided simulation submodel (22), and the interface (3) transmits the data (DMS22) received from the second computer-aided simulation submodel (22) to the first computer-aided simulation submodel (21). [12] Method according to any of the foregoing claims, characterized by , that the interface (3) manipulates the data to be transmitted (DB1, DM1) according to an adjustable specification, wherein the manipulation in particular provides for the addition of an offset and / or the application of a scaling factor. [13] Interface (3) with inputs (331, 332) for receiving data (DB1, DM1) and outputs (341, 342) for outputting data (DB1, DM1), wherein at least one first input (331) of the interface (3) is configured to receive data (DB1) from a processing station (1), and wherein at least one first output (341) of the interface (3) is configured to transmit the data (DB1) received from the processing station (1) to a computer simulation model (2) of the processing station (1). [14] Interface according to claim 13, characterized by , that at least a second input (332) of the interface (3) is configured to receive data (DM1) from the computer-aided simulation model (2), and that at least a second output (342) of the interface (3) is configured to transmit the data (DM1) received from the computer-aided simulation model (2) to the processing station (1). [15] Interface according to claim 13 or claim 14, characterized by , that the interface (3) is designed for the transfer of data (DB1, DM1) between a processing station (1) and a computer-aided simulation model (2) according to a method according to one of claims 1 to 12.

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