Digital device

Abstract

To reproduce a further correct state of a real device using operation-state data indicative of a behavior of the real device.SOLUTION: An industrial machine control system comprises a real device that includes a control device to control an industrial machine and a digital device that imitates the real device by software, the digital device having an input section to input operation-state data acquired in the real device to the digital device. By the operation state data inputted to the input section, the real device is imitated with the digital device.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an industrial machine control system.

Background Art

[0002] Digital simulators that model real devices consisting of industrial machines and drive devices such as control devices, motors, and amplifiers that control and drive them, based on theoretical values for each of the industrial machines, control devices, drive devices, etc., have been developed conventionally. In addition, such digital simulators generally have a structure in which each device is reproduced software-wise. In this regard, there is a technology known that creates and debugs software for operating a control device that controls field devices installed in a plant, and has a cloud that simulates the operating state of the control device according to the simulation input or input to the control device and the software, and debugs the software based on the operating result of the simulation and the output from the control device or the simulation input, thereby enabling high-quality engineering. For example, see Patent Document 1.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Digital simulators such as those in Patent Document 1 individually simulate and imitate real devices consisting of industrial machines and drive devices such as control devices, motors, and amplifiers that control and drive them, but there are limitations to such simulation and imitation, and it is difficult to accurately reproduce the behavior of real devices. The reason is that real devices have elements that cannot be easily simulated by software, such as communication delays, mechanical losses, the performance of the CPU (Central Processing Unit), changes due to the surrounding environment, etc.

[0005] Therefore, it is desired to reproduce the state of a real device more accurately using the operation state data indicating the behavior of the real device.

Means for Solving the Problem

[0006] One aspect of the industrial machine control system of the present disclosure is an industrial machine control system including a real device including a control device for controlling an industrial machine and a digital device that emulates the real device in software, wherein the digital device includes an input unit that inputs operation state data acquired in the real device into the digital device, and emulates the real device with the digital device based on the operation state data input to the input unit.

Advantages of the Invention

[0007] According to one aspect, it is possible to reproduce the state of a real device more accurately using the operation state data indicating the behavior of the real device.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3A

Figure 3B

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Embodiments for Carrying Out the Invention

[0009] <One Embodiment> FIG. 1 is a functional block diagram showing a functional configuration example of an industrial machine control system according to one embodiment. Here, a machine tool is exemplified as an industrial machine, and a numerical control device is exemplified as a control device. Note that the present invention is not limited to a machine tool and a numerical control device, and is applicable to, for example, industrial machines such as injection molding machines, industrial robots, service robots, and robot control devices that control industrial robots. As shown in FIG. 1, the industrial machine control system 1 includes a machine tool 10 as a real device and a digital device 20. The machine tool 10 and the digital device 20 may be directly connected to each other via a connection interface (not shown). Note that the machine tool 10 and the digital device 20 may be connected to each other via a network (not shown) such as a LAN (Local Area Network) or the Internet. In this case, the machine tool 10 and the digital device 20 are provided with a communication unit (not shown) for communicating with each other by such a connection.

[0010] <Machine tool 10> The machine tool 10 is a machine tool known to those skilled in the art, and includes a numerical control device 11 as a control device, a drive device 12, a peripheral device 13, and an information collection device 14. The machine tool 10 operates based on an operation command of the numerical control device 11 described later. Note that each of the numerical control device 11, the drive device 12, the peripheral device 13, and the information collection device 14 is included in the machine tool 10, but may be a device different from the machine tool 10.

[0011] The numerical control device 11 is a numerical control device known to those skilled in the art. For example, the numerical control device 11 generates an operation command based on a machining program obtained from a CAD / CAM device (not shown) or the like, and transmits the generated operation command to the machine tool 10. Thereby, the numerical control device 11 controls the operation of the machine tool 10. Note that when the machine tool 10 is a robot or the like, the numerical control device 11 may be a robot control device or the like. While controlling the machine tool 10, the numerical control device 11 outputs information regarding the signal processing speed and the processing ability of the CPU, and information such as the amount of electric power as operation state data R to the information collection device 14 described later.

[0012] Based on the commands from the numerical control device 11, the drive device 12 drives a spindle motor (not shown) included in the machine tool 10 via an amplifier (not shown) included in the drive device 12. Specifically, for example, while feeding back information including the position and speed of a motor (not shown) detected by an encoder (not shown) as a signal, the drive device 12 drives the motor (not shown). Note that the motor (not shown) is applicable to various motors used for the feed shaft or spindle of a machine tool, or for the arm of an industrial machine or industrial robot, etc. While driving an amplifier and a motor (not shown), the drive device 12 outputs information regarding the behavior of the motor and the machine (such as speed, motor temperature, etc.) as operation state data R to an information collection device 14 described later.

[0013] The peripheral device 13 is, for example, a belt conveyor or the like, and operates based on the commands from the numerical control device 11. While operating, the peripheral device 13 outputs information regarding the surrounding environment such as temperature as operation state data R to an information collection device 14 described later.

[0014] The information collection device 14 is, for example, a computer or the like, and includes an operation state data R acquisition unit 141. The information collection device 14 is equipped with an arithmetic processing device such as a CPU. Further, the information collection device 14 also includes an auxiliary storage device such as an HDD (Hard Disk Drive) that stores various control programs such as application software and an OS (Operating System), and a main storage device such as a RAM (Random Access Memory) for storing data that is temporarily required for the arithmetic processing device to execute the program. Then, in the information collection device 14, the arithmetic processing unit reads application software and the OS from the auxiliary storage device, expands the read application software and the OS in the main storage device, and performs arithmetic processing based on these application software and the OS. Further, based on this arithmetic result, various hardware components included in the information collection device 14 are controlled. Thereby, the functional blocks of the present embodiment are realized. That is, the present embodiment can be realized by the cooperation of hardware and software.

[0015] The operation state data R acquisition unit 141 acquires the operation state data R output from each of the numerical control device 11, the drive device 12, and the peripheral device 13, and outputs the acquired operation state data R to the digital device 20 described later.

[0016] Note that in the industrial machine control system 1 according to the present embodiment, the information collection device 14 is arranged in the machine tool 10, but may be arranged in the digital device 20.

[0017] <Digital device 20> The digital device 20 is, for example, a computer or the like, and includes an input unit 21, a control unit 22, and a storage unit 23. Further, the control unit 22 includes a simulation execution unit 220. Further, the simulation execution unit 220 includes an operation state data difference generation unit 221.

[0018] The input unit 21 inputs the operation state data R acquired in the machine tool 10 as a real device into the digital device 20. Specifically, the input unit 21 inputs, for example, the operation state data R of each of the numerical control device 11, the drive device 12, and the peripheral device 13 of the machine tool 10 acquired by the information collection device 14 of the machine tool 10 into the digital device 20.

[0019] The storage unit 23 is a RAM, an HDD, or the like, and stores the operation state data R, the operation state difference data 231, and the operation state data D. As described above, the operation state data R is the operation state data R of each of the numerical control device 11, the drive device 12, and the peripheral device 13 of the machine tool 10 acquired by the information collection device 14 of the machine tool 10. The operation state difference data 231 is data obtained by taking the difference between the operation state data R of each of the numerical control device 11, the drive device 12, and the peripheral device 13 and the operation state data D of each of the numerical control device 11, the drive device 12, and the peripheral device 13 simulated by the simulation execution unit 220 described later by the operation state data difference generation unit 221 described later. The operation state data D is the operation state data D of each of the numerical control device 11, the drive device 12, and the peripheral device 13 simulated (imitated) by the simulation execution unit 220 described later.

[0020] The control unit 22 includes a CPU, a ROM, a RAM, a CMOS (Complementary Metal-Oxide-Semiconductor) memory, etc., which are configured to be communicable with each other via a bus, and are well-known to those skilled in the art. The CPU is a processor that controls the entire digital device 20. The CPU reads out the system program and the application program stored in the ROM via the bus, and controls the entire digital device 20 according to the system program and the application program. As a result, as shown in FIG. 1, the control unit 22 is configured to realize the function of the simulation execution unit 220. Further, the simulation execution unit 220 is configured to realize the function of the operation state data difference generation unit 221. Various data such as temporary calculation data and display data are stored in the RAM. The CMOS memory is configured as a non-volatile memory backed up by a battery (not shown) and retains the storage state even when the power of the digital device 20 is turned off.

[0021] The simulation execution unit 220 executes a simulation to operate the numerical control device 11, the drive device 12, and the peripheral device 13 respectively based on the machining program executed by the machine tool 10, and acquires operation state data D indicating the operation and / or state of each of the numerical control device 11, the drive device 12, and the peripheral device 13. The simulation execution unit 220 stores the acquired operation state data D of each of the numerical control device 11, the drive device 12, and the peripheral device 13 in the storage unit 23.

[0022] The operation state data difference generation unit 221 calculates the difference between the operation state data R and the operation state data D for each of the numerical control device 11, the drive device 12, and the peripheral device 13, and generates operation state difference data 231. The operation state data difference generation unit 221 stores the generated operation state difference data 231 of each of the numerical control device 11, the drive device 12, and the peripheral device 13 in the storage unit 23. In the industrial machine control system 1 according to the present embodiment, the operation state data difference generation unit 221 is arranged in the digital device 20, but may be arranged in the information collection device 14 of the machine tool 10, or may be arranged in both the information collection device 14 and the digital device 20. When the operation state data difference generation unit 221 is arranged in the information collection device 14, the digital device 20 may output the operation state data D of each of the numerical control device 11, the drive device 12, and the peripheral device 13 simulated by the simulation execution unit 220 to the information collection device 14 of the machine tool 10.

[0023] Next, regarding the operation of the industrial machine control system 1, (A) when reproducing the operation of the machine tool 10 using the actual signal processing speed, (B) when reproducing the operation of the machine tool 10 using the actual feedback amount, (C) when correcting the machining program according to the CPU performance of the actual numerical control device 11, (D) when correcting the machining program based on the actual power consumption of the machine tool 10, and (E) when reproducing the occurrence of an overheat alarm using the motor temperature of the machine tool 10 will be described respectively.

[0024] (A) Regarding the case of reproducing the operation of the ladder control device using the actual signal processing speed FIG. 2 is a diagram showing an operation example of the industrial machine control system 1 when reproducing the operation of the ladder control device using the actual signal processing speed. As shown in FIG. 2, the numerical control device 11 of the machine tool 10 implements and executes a ladder program in, for example, a ladder control device (not shown) connected to the numerical control device 11 on the machine tool 10. The numerical control device 11 measures the signal processing speed while controlling the machine tool 10, and outputs information regarding the measured signal processing speed to the information collection device 14 as operation state data R. The information collection device 14 outputs the operation state data R of the numerical control device 11 to the digital device 20. The digital device 20 adjusts to the signal processing speed at the time of the same implementation as the machine tool 10 based on the signal processing speed included in the operation state data R acquired from the machine tool 10, and simulates the ladder program.

[0025] Specifically, for example, when a ladder control device (not shown) executes each instruction of the ladder program, the numerical control device 11 measures the processing time of each instruction as the signal processing speed. FIG. 3A is a diagram showing an example of an instruction of the ladder program. FIG. 3B is a diagram showing an example of a timing chart of the instruction of FIG. 3A. Note that, although the case of the instruction shown in FIG. 3A will be described, the signal processing speed is measured in the same manner as in the case of FIG. 3A for other instructions. For example, when a ladder control device (not shown) executes an instruction to write data to the numerical control device 11 shown in FIG. 3A, the numerical control device 11 measures the time t from the time t1 when the ladder control device (not shown) outputs an ACT signal for instruction execution until the time t3 when the processing of the functional instruction is completed internally in the ladder control device (not shown) as the processing time of the instruction. Note that, since the times t4 to t6 when the completion signal W1 returns are for the subsequent ladder execution cycles, the numerical control device 11 can acquire the accurate processing time of the ladder control device (not shown) by measuring the time t from the time t1 to the time t3. The numerical control device 11 inputs the processing times of all the instructions included in the ladder program to the digital device 20 via the information collection device 14 as the signal processing speed of the operation state data R.

[0026] The digital device 20 corrects the processing time of the instructions of the ladder program in the digital device 20 according to the input processing time. Thereby, the digital device 20 can execute the ladder program at the same timing as the machine tool 10. In other words, conventionally, even though the logic could be reproduced by the simulator, the actual processing speed (response speed) could not be reproduced, so there were sometimes problems with signal timing during implementation. However, the digital device 20 can achieve accurate reproduction by inputting the signal processing speed to the digital device 20.

[0027] (B) Regarding the case of reproducing the operation of the machine tool 10 using the actual feedback amount FIG. 4 is a diagram showing an operation example of the industrial machine control system 1 when reproducing the operation of the machine tool 10 using the actual feedback amount. As shown in FIG. 4, the numerical control device 11 of the machine tool 10 generates a position command for each block of the machining program and generates a speed command based on the generated position command by executing the machining program. The numerical control device 11 calculates a position deviation from the generated position command and the position feedback (feedback amount) indicating the actual position of the machine MA such as the spindle included in the machine tool 10, and corrects the position command with the calculated position deviation. Further, the numerical control device 11 calculates a speed deviation from the generated speed command and the speed feedback (feedback amount) indicating the actual speed of the motor MO driven by the drive device 12, and corrects the speed command with the calculated speed deviation. The numerical control device 11 outputs the corrected position command and speed command to the drive device 12. Further, the numerical control device 11 may generate a current command (torque command) by applying, for example, PI (proportional, integral) control to the obtained speed deviation. The numerical control device 11 may output the current command corrected by the current deviation between the generated current command and the current feedback (feedback amount) output by the drive device 12 to the motor MO to the drive device 12.

[0028] The information collection device 14 acquires position feedback, speed feedback, and current feedback as operation state data R from the numerical control device 11 together with position commands, speed commands, and current commands. The information collection device 14 outputs the acquired operation state data R of the numerical control device 11 to the digital device 20.

[0029] The simulation execution unit 220 of the digital device 20 executes a simulation of the machine tool 10 based on the acquired operation state data R and the machining program. Specifically, the simulation execution unit 220 operates, for example, a drive device model M1 that models the drive device 12, a motor model M2 that models the motor MO, and a machine model M3 that models the machine MA based on the machining program, and calculates the feedback amounts of current feedback from the drive device model M1, speed feedback from the motor model M2, and position feedback from the machine model M3. The simulation execution unit 220 compares the feedback amounts of current feedback, speed feedback, and position feedback included in the operation state data R acquired from the machine tool 10 with the calculated feedback amounts of current feedback, speed feedback, and position feedback, and inputs the difference in the feedback amounts of each feedback to simulate position control, speed control, and current control. By doing so, in the digital device 20, although it was difficult for conventional simulators to accurately match the behavior of the actual motor and the behavior of the machine, accurate reproduction becomes possible by inputting the difference in the feedback amounts between the machine tool 10 and the digital device 20 to the digital device 20.

[0030] The drive device model M1 and the motor model M2 are created using, for example, known methods such as International Publication No. 2020 / 003738. The machine model M3 is created using, for example, known methods such as "Research on Low-Frequency Vibration Suppression Control Using a Two-Inertia System Model for the Feed Axis of an NC Machine Tool", Vol. 82, No. 8, pp. 745-750, 2016, Transactions of the Japan Society for Precision Engineering.

[0031] In addition, in FIG. 4, the industrial machine control system 1 inputs the difference in the feedback amount between the machine tool 10 and the digital device 20 to the digital device 20, but is not limited thereto. For example, the industrial machine control system 1 may directly input the feedback amounts of current feedback, speed feedback, and position feedback for the numerical control device 11 included in the operation state data R acquired in the machine tool 10 to the digital device 20. FIG. 5 is a diagram showing an operation example of the industrial machine control system when reproducing the operation of the machine tool 10 using the actual feedback amount. Note that elements having the same functions as those in FIG. 4 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. In addition, in the digital device 20, the motor model M2 and the mechanical model M3 are omitted. By doing so, in the conventional simulator, it was difficult to accurately match the behavior of the actual motor and the behavior of the machine, but the industrial machine control system 1 can achieve more accurate reproduction by inputting the feedback amount of the machine tool 10 to the digital device 20.

[0032] (C) Case of modifying the machining program according to the CPU performance of the actual numerical control device 11 FIG. 6 is a diagram showing an operation example of the industrial machine control system 1 when modifying the machining program according to the CPU performance of the actual numerical control device 11. Note that elements having the same functions as those in FIG. 4 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. As shown in FIG. 6, the numerical control device 11 measures BPTmin, which is the limit value (minimum value) of the command processing speed (for example, BPT: Block Processing Time) of the numerical control device 11, as will be described later. The digital device 20 acquires the operation state data R including the information indicating the relationship between the block length of the machining program and BPT in the numerical control device 11 and BPTmin via the information collection device 14, and matches it with BPTmin of the numerical control device 11 in the simulation. The digital device 20 executes the simulation, determines the margin according to whether or not BPTmin is reached, and modifies the machining program according to BPTmin of the numerical control device 11 by adding / deleting the command points of the machining program.

[0033] Specifically, the numerical control device 11 operates the machine tool 10 by executing a machining program for testing in which the block length changes under the condition of a constant feed rate, measures the limit value (BPTmin) of the BPT, and obtains the relationship (function) between the block length and the BPT. FIG. 7 is a diagram showing an example of a machining program for testing for measuring BPTmin. In FIG. 7, one block of the machining program for testing is shown. As shown in FIG. 7, in order to obtain the relationship (function) between the block length and the BPT, the numerical control device 11 changes the block length of the machining program for testing at a predetermined ratio (for example, 1 / 10, etc.) and measures the minimum value of the block length until deceleration occurs by reducing the block length. FIG. 8 is a diagram showing an example of the relationship between the block length and the BPT. Note that BPT (s / block) is the block length (mm / block) / feed rate (mm / ms), which is an index representing the performance of the numerical control device 11 and changes depending on the CPU performance included in the numerical control device 11. Also, BPTmin is the minimum value of the block length / command feed rate. As shown in FIG. 8, as the block length shortens to the block length BL0, the BPT decreases. When the block length becomes shorter than the block length BL0, the BPT becomes a constant value "α". That is, the minimum value "α" of the BPT is the limit value and becomes BPTmin.

[0034] The information collection device 14 outputs the operation state data R including the relationship (function) between the block length and the BPT in FIG. 7 and BPTmin, which are acquired by the numerical control device 11, to the digital device 20.

[0035] The simulation execution unit 220 of the digital device 20 adjusts the BPTmin when executing the machining program in the simulation to the BPTmin included in the operation state data R. In other words, although the limit value of the BPT is smaller in the simulation of the digital device 20 (the program can be processed more finely and faster), the BPTmin is made to match the machine tool 10. Then, when the simulation execution unit 220 operates the machining program in the simulation, it determines whether a command feed rate is output (i.e., whether deceleration occurs), and adds, deletes, and corrects the command points of the machining program according to the determination result. For example, when the command feed rate is output (no deceleration), the simulation execution unit 220 adds command points (reduces the block length) to the machining program, and when the command feed rate is not output (deceleration occurs), the simulation execution unit 220 deletes command points (increases the block length) from the machining program.

[0036] FIG. 9 is a diagram showing an example of adding or deleting command points of a machining program by the simulation execution unit 220. As shown in the lower part of FIG. 9, when the command feed rate is not output (deceleration occurs), the simulation execution unit 220 deletes command points from the machining program, that is, increases the block length, so that the command feed rate is output. On the other hand, for example, when the command feed rate is output with an original block length of 0.1 mm in the machining program, the simulation execution unit 220 performs simulation again with a machining program in which the block length is changed to 0.05 mm, 0.01 mm, etc., that is, command points are added. When the simulation execution unit 220 does not decelerate at a block length of 0.05 mm and decelerates at a block length of 0.01 mm, as shown in the upper part of FIG. 9, the simulation execution unit 220 adds and corrects command points to the machining program so that the block length becomes 0.05 mm. The digital device 20 transmits the corrected machining program to the machine tool 10. Thereby, the digital device 20, unlike conventional simulators, did not consider the actual numerical control processing ability. However, by inputting the command processing ability (BPT processing ability) of the numerical control device 11 into the digital device 20, the machining program can be optimized according to the command processing ability of the numerical control device 11.

[0037] (D) Regarding the case of correcting the machining program based on the power consumption of the actual machine tool 10 FIG. 10 is a diagram showing an operation example of the industrial machine control system 1 when modifying a machining program based on the power consumption of the actual machine tool 10. Note that elements having the same functions as those in FIG. 4 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. Further, in FIG. 10, illustration of the current feedback of the drive device 12, the speed feedback of the motor MO, and the position feedback of the machine tool MA is omitted. As will be described later, the numerical control device 11 measures the power consumption (instantaneous value per speed) of the machine tool 10 according to the feed rate or the spindle rotation speed, and obtains the relationship (function) between the feed rate or the spindle rotation speed - power consumption. The digital device 20 acquires the operation state data R including the relationship (function) between the speed or the spindle rotation speed - power consumption measured by the numerical control device 11 via the information collection device 14. In the simulation executed by the digital device 20, the total power consumption of the machine tool 10 is calculated by integrating the power consumption during the operation of the machining program using the obtained relationship (function) between the speed or the spindle rotation speed - power consumption as the drive device power model M4. The digital device 20 corrects the feed rate or the spindle rotation speed of the machining program at which the total power consumption including the machining time becomes minimum.

[0038] Specifically, for example, the numerical control device 11 operates the machine tool 10 by executing a test machining program in which the feed rate (or the spindle rotation speed) changes, measures the instantaneous power consumption for each feed rate (or the spindle rotation speed), and obtains the relationship (function) between the feed rate (or the spindle rotation speed) - power consumption as shown in FIG. 11. The information collection device 14 outputs the operation state data R including the relationship (function) between the feed rate (or the spindle rotation speed) - power consumption in FIG. 11 obtained by the numerical control device 11 to the digital device 20.

[0039] In the simulation execution unit 220 of the digital device 20, in the simulation being executed, the total power consumption during the operation is calculated by calculating and adding the instantaneous power consumption when the machining program is operated for each feed rate (or the spindle rotation speed) in the simulation using the relationship (function) between the feed rate (or the spindle rotation speed) - power consumption included in the operation state data R as the drive device power model M4. FIG. 12 is a diagram showing an example of the relationship between the feed rate (or spindle rotation speed) and the total power consumption. As shown in FIG. 12, for example, when the original feed rate set in the machining program is F2000 [mm / min], the simulation execution unit 220 calculates the total power consumption to be 100 Wh by simulation. Further, the simulation execution unit 220 calculates the total power consumption to be 80 Wh, 40 Wh, and 60 Wh by simulation when the feed rate of the machining program is changed to F1000 [mm / min], F1500 [mm / min], and F3000 [mm / min], respectively. Based on the simulation results, the simulation execution unit 220 corrects the machining program so that the feed rate changes from F2000 [mm / min] to F1500 [mm / min] at which the power consumption is minimized. The digital device 20 transmits the corrected machining program to the machine tool 10. By doing so, the digital device 20, which was difficult to reproduce the actual power consumption only with a theoretical model in a conventional simulator, can reproduce an accurate power simulation by inputting the power waveform measured by the machine tool 10 into the digital device 20.

[0040] (E) Regarding the case of reproducing the occurrence of an overheat alarm using the motor temperature of the machine tool 10 FIG. 13 is a diagram showing an operation example of the industrial machine control system 1 when reproducing the occurrence of an overheat alarm using the motor temperature of the machine tool 10. Note that elements having the same functions as those in FIG. 4 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. Similar to the case of FIG. 4, the numerical control device 11 obtains position feedback, speed feedback, and current feedback as operation state data R together with position commands, speed commands, and current commands by executing a machining program. Further, the numerical control device 11 also obtains, as operation state data R, information indicating the relationship between the rotation speed (or current) of the motor MO, the rotation time of the motor MO, and the motor temperature measured by a temperature sensor (not shown) provided in the motor MO, i.e., how long the motor MO has been rotated. The digital device 20 obtains the operation state data R in the numerical control device 11 via the information collection device 14, and uses the relationship between the rotation speed (or current) of the motor MO measured by the numerical control device 11, the operation time of the motor MO, and the motor temperature of the motor MO to correct the motor temperature in the motor model M2, thereby simulating the occurrence of an overheat alarm.

[0041] Specifically, for example, the numerical control device 11 measures the relationship between the rotation time and the motor temperature for each rotation speed (or current) by executing a machining program for testing that changes the rotation speed (or current). FIG. 14 is a diagram showing an example of the relationship between the rotation time and the motor temperature for each rotation speed (or current). In FIG. 14, “S1000” and “S10000” are commanded as the rotation speeds in the machining program, and the relationship between the respective rotation times and the motor temperature is measured. Note that in FIG. 14, a threshold value at which an overheat alarm is issued is set in advance.

[0042] The information collection device 14 outputs the operation state data R including the relationship (function) between the rotation time and the temperature in FIG. 14 to the digital device 20 together with the rotation speed (or current) of the motor MO and the rotation time of the motor MO obtained by the numerical control device 11.

[0043] The simulation execution unit 220 of the digital device 20 corrects the motor temperature by comparing the motor temperature calculated from the relationship (function) between the rotation time and the temperature included in the acquired operating state data R with the motor temperature calculated from the motor model M2 and inputting the difference. As a result, the simulation execution unit 220 can accurately simulate (imitate) the occurrence of the overheat alarm. In other words, in the digital device 20, it was difficult for a conventional simulator to reproduce the actual motor temperature only with a theoretical model. However, by inputting the difference between the motor temperature measured by the machine tool 10 and the motor temperature of the digital device 20 into the digital device 20, it becomes possible to reproduce an accurate temperature simulation, and it becomes possible to perform preventive maintenance of the overheat alarm of the motor MO.

[0044] Note that the numerical control device 11 acquires information on how long the motor MO including the relationship (function) between the rotation time and the temperature in FIG. 14 has been rotated together with the rotation speed (or current) of the motor MO and the rotation time of the motor MO, and the information collection device 14 outputs the operating state data R including the information to the digital device 20, but it is not limited thereto. For example, the numerical control device 11 may only measure the motor temperature T0 of the motor MO at the time of stop, the motor temperature Tr1 of the motor MO at the time of cutting, and the cutting speed F1. The information collection device 14 outputs the motor temperature T0 of the motor MO measured by the numerical control device 11 at the time of stop, the motor temperature Tr1 of the motor MO at the time of cutting, and the cutting speed F1 to the digital device 20. Since the heat generation of the motor can calculate the theoretical heat generation from the current value and winding resistance of the motor, the theoretical temperature value with respect to the motor temperature T0 of the motor MO at the time of stop is "0" degrees. Also, the theoretical temperature value with respect to the motor temperature Tr1 of the motor MO at the time of cutting is calculated as Td1.

[0045] The simulation execution unit 220 of the digital device 20 calculates the difference (Tr1 - Td1 - T0) (= ΔT) between the measured motor temperature and the theoretical temperature value Td1. The simulation execution unit 220 linearly and proportionally distributes ΔT from a speed of 0 to a cutting speed F1, and calculates the temperature T at the actual speed F as the theoretical temperature value Td1 + T0 + (ΔT / cutting speed F1) × actual speed F. Note that the motor temperature T0 includes the ambient temperature, the differential ΔT includes heat generation due to loads caused by mechanical friction and tool wear, and heat generation due to individual differences in products caused by variations in physical constants (resistance values). The digital device 20 enables more accurate simulation and can accurately simulate (imitate) the occurrence of overheat alarms.

[0046] As described above, the industrial machine control system 1 according to one embodiment can reproduce the state of the machine tool 10 more accurately than conventional simulators by inputting operation state data indicating the behavior of the machine tool 10 into the digital device 20. Also, the industrial machine control system 1 can accurately correct the set values and control programs related to the control existing in the machine tool 10 in a short time by performing the simulation one or more times using the highly accurate information reproduced by the digital device 20.

[0047] Although one embodiment has been described above, the industrial machine control system 1 is not limited to the above-described embodiment and includes modifications, improvements, etc. within the range that can achieve the object.

[0048] <Modification Example 1> In one embodiment, the machine tool 10 includes a numerical control device 11, a drive device 12, a peripheral device 13, and an information collection device 14, but is not limited thereto. For example, each of the numerical control device 11, the drive device 12, the peripheral device 13, and the information collection device 14 may be a device different from the machine tool 10. Also, the numerical control device 11 may include the digital device 20.

[0049] <Modification Example 2> Also, for example, in one embodiment, the digital device 20 performs preventive maintenance of the overheat alarm of the motor MO by comparing the measured motor temperature of the motor MO with the simulated motor temperature of the motor model M2 and inputting the difference into the digital device 20, but is not limited thereto. For example, the operating state data R includes operation information such as the operating time, cutting time, and spindle rotation speed of components such as ball screws, bearings, and spindles included in the machine tool 10. The digital device 20 compares the operation information included in the acquired operating state data R with the operation information obtained by simulation and inputs the difference into the digital device 20, thereby simulating the replacement timing of components such as ball screws.

[0050] Each function included in the industrial machine control system 1 according to one embodiment can be realized by hardware, software, or a combination thereof. Here, being realized by software means being realized by a computer reading and executing a program.

[0051] The program can be stored using various types of non-transitory computer readable media and supplied to a computer. Non-transitory computer readable media include various types of tangible storage media. Examples of non-transitory computer readable media include magnetic recording media (e.g., flexible disks, magnetic tapes, hard disk drives), magneto-optical recording media (e.g., magneto-optical disks), CD-ROM (Read Only Memory), CD-R, CD-R / W, semiconductor memories (e.g., mask ROM, PROM (Programmable ROM), EPROM (Erasable PROM), flash ROM, RAM). Also, the program may be supplied to the computer by various types of transitory computer readable media. Examples of transitory computer readable media include electrical signals, optical signals, and electromagnetic waves. The transitory computer readable media can supply the program to the computer via wired communication paths such as electric wires and optical fibers, or wireless communication paths.

[0052] Note that the steps of describing the program recorded on the recording medium include not only the processes performed in chronological order along that sequence, but also processes that may be executed in parallel or individually without necessarily being processed in chronological order.

[0053] In other words, the industrial machine control system of the present disclosure can take various embodiments having the following configurations.

[0054] (1) The industrial machine control system 1 of the present disclosure comprises a real device including a numerical control device 11 for controlling a machine tool 10 and a digital device 20 that emulates the real device in software. The digital device 20 is provided with an input unit 21 that inputs operation state data R acquired in the real device into the digital device 20, and emulates the real device with the digital device 20 based on the operation state data R input to the input unit 21. According to this industrial machine control system 1, it is possible to reproduce the state of the real device more accurately using the operation state data indicating the behavior of the real device.

[0055] (2) In the industrial machine control system 1 described in (1), the operation state data may include difference data between the operation state data R of the real device and the operation state data D of the digital device 20. By doing so, the industrial machine control system 1 can achieve more accurate reproduction.

[0056] (3) In the industrial machine control system 1 described in (1), the operation state data may include at least one of the operation state data R measured from the real device, the detected operation state data R, or the control amount created within the real device. By doing so, the industrial machine control system 1 can achieve the same effect as in (2).

[0057] (4) In the industrial machine control system 1 described in (2), the digital device 20 may correct the program executed in the real device or the parameters set in the real device by inputting the difference data. By doing so, the industrial machine control system 1 can improve the design efficiency in the design (application development) of the industrial machine and can improve the productivity in the operation (processing) of the industrial machine.

[0058] (5) In the industrial machine control system 1 according to any one of (1) to (4), the operating state data R may include at least any one of signal processing speed, feedback amount, CPU performance, power consumption, or motor temperature. By doing so, the industrial machine control system 1 can accurately reproduce the real device according to the situation.

[0059] (6) In the industrial machine control system 1 according to (5), when the operating state data R is the signal processing speed, the digital device 20 may reproduce the operation of the machine tool 10 using the processing time for each instruction included in the program. By doing so, the industrial machine control system 1 can execute the program at the same timing as the machine tool 10.

[0060] (7) In the industrial machine control system 1 according to (5), when the operating state data R is the feedback amount, the digital device 20 may reproduce the operation of the machine tool 10 using at least any one of the feedback amounts of position feedback, speed feedback, or current feedback. By doing so, the industrial machine control system 1 can accurately match the behavior of the motor and the machine of the actual machine tool 10.

[0061] (8) In the industrial machine control system 1 according to (5), when the operating state data R is the CPU performance, the digital device 20 may correct the program using the limit value of the command processing speed of the numerical control device 11 and the information indicating the relationship between the block length of the program and the command processing speed. By doing so, the industrial machine control system 1 can optimize the program in consideration of the processing capacity of the actual numerical control device 11.

[0062] (9) In the industrial machine control system 1 according to (5), when the operating state data R is the power consumption, the digital device 20 may correct the program using the relationship between the feed speed or the spindle rotation speed of the motor MO included in the machine tool 10 and the power consumption at the time of the feed speed or the spindle rotation speed. By doing so, the industrial machine control system 1 can accurately reproduce the power consumption of the machine tool 10.

[0063] (10) In the industrial machine control system 1 described in (5), when the operation state data R is the motor temperature, the digital device 20 may reproduce the occurrence of an alarm related to the motor MO by using information indicating the relationship between the rotation speed or current of the motor MO included in the machine tool 10, the rotation time of the motor MO, and the motor temperature of the motor MO. By doing so, the industrial machine control system 1 can perform preventive maintenance of the alarm related to the motor MO.

[0064] (11) In the industrial machine control system 1 described in (8) or (9), the digital device 20 may transmit the modified program to the machine tool 10. By doing so, the industrial machine control system 1 can optimize the program executed by the machine tool 10.

Explanation of Signs

[0065] 1 Industrial machine control system 10 Machine tool 11 Numerical control device 12 Driving device 13 Peripheral device 14 Information collection device 20 Digital device 21 Input unit 22 Control unit 220 Simulation execution unit 221 Operation state data difference generation unit 23 Storage unit R Operation state data 231 Operation state difference data D Operation state data

Claims

1. An industrial machine control system comprising a real device including a control device for controlling an industrial machine and a digital device that imitates the real device by software, the digital device includes an input unit that inputs operational status data acquired in the real device to the digital device; The industrial machine control system imitates the real device with the digital device based on the operation status data input to the input section.

2. 2. The industrial machine control system according to claim 1, wherein the operation status data includes differential data between the operation status data of the real device and the operation status data of the digital device.

3. The industrial machine control system according to claim 1 , wherein the operating status data includes at least one of operating status data measured from the real device, operating status data detected, or a control amount created within the real device.

4. 3. The industrial machine control system according to claim 2, wherein the digital device corrects a program executed in the real device or a parameter set in the real device by inputting the difference data.

5. The industrial machine control system according to claim 1 , wherein the operation status data includes at least any one of a signal processing speed, a feedback amount, a CPU performance, a power consumption, and a motor temperature.

6. 6. The industrial machine control system according to claim 5, wherein said digital device reproduces the operation of said real device using a processing time for each instruction included in a program when said operation status data is said signal processing speed.

7. 6. The industrial machine control system according to claim 5, wherein, when the operational status data is the feedback amount, the digital device reproduces the operation of the real device using at least one of a position feedback, a speed feedback, and a current feedback amount.

8. 6. The industrial machinery control system according to claim 5, wherein when the operating status data is the CPU performance, the digital device modifies the program using information indicating a limit value of the command processing speed of the control device and a relationship between a block length of the program and the command processing speed.

9. 6. The industrial machinery control system according to claim 5, wherein, when the operating status data is the power consumption, the digital device modifies a program using a relationship between a feed speed or a spindle speed of a motor included in the real device and the power consumption at the feed speed or the spindle speed.

10. 6. The industrial machinery control system according to claim 5, wherein, when the operating status data is the motor temperature, the digital device reproduces the occurrence of an alarm related to the motor using information included in the real device indicating a relationship between the motor rotation speed or current, the rotation time of the motor, and the motor temperature of the motor.

11. 10. The industrial machine control system according to claim 8, wherein the digital device transmits a modified version of the program to the real device.

Images