Simulation system

Abstract

To provide a simulation system capable of debugging control software without operating an actual device even when the control specifications of the actual device are unknown.SOLUTION: A simulation system comprises a provisional simulation model M2, a control command value output unit 10, and a virtual controller unit 60. The provisional simulation model M2 simulates the operation of an actual device 100 on the basis of the provisional specifications different from the control specifications of the actual device 100. The control command value output unit 10 outputs a control command value V according to control software S. The virtual controller unit 60 operates the provisional simulation model M2 according to the control command value V. According to this configuration, even if the actual control specifications are unknown, the appropriateness of the control command value V output from the control software S can be evaluated using the provisional simulation model M2. As a result, it becomes possible to debug the control software S without operating the actual device 100.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a simulation system for simulating the operation of a real device on a computer. [Background technology]

[0002] Conventionally, simulation systems such as HILS (Hardware In The Loop Simulation) and SILS (Software In The Loop Simulation) are known. These simulation systems simulate the operation of real equipment using control software on a computer. Using these simulation systems, it is possible to debug control software without operating the real equipment.

[0003] A conventional simulation system is described in, for example, Patent Document 1. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-295126 Summary of the Invention [Problem to be solved by the invention]

[0005] However, conventional simulation systems are based on the assumption that the control specifications of the actual device are known. With conventional methods, if the control specifications of the actual device are unknown, it is not possible to create a simulation model. In such cases, the actual device must be operated in order to debug the control software.

[0006] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a simulation system that can debug control software without operating the actual device, even when the control specifications of the actual device are unknown. [Means for solving the problem]

[0007] In order to solve the above problems, the first invention of the present application is a simulation system using a computer, comprising: a virtual simulation model that simulates the operation of a real device on a computer using virtual specifications that differ from the control specifications of the real device; a control command value output unit that outputs control command values ​​used to control the real device in accordance with control software installed on the computer; a memory that stores the control command values; and a virtual controller unit that operates the virtual simulation model in accordance with the control command values ​​read from the memory.

[0008] A second aspect of the present invention is the simulation system of the first aspect of the present invention, further comprising a real controller unit that controls the real device in accordance with the control command value read from the memory.

[0009] A third invention of the present application is a simulation system of the first or second invention, wherein the real device includes a first unit whose control specifications are known and a second unit whose control specifications are unknown, and the simulation system is equipped with a simulator having a first simulation model that simulates the operation of the first unit on a computer according to the control specifications of the first unit, and a second simulation model that is a provisional simulation model that simulates the operation of the second unit on a computer according to provisional specifications different from the control specifications of the second unit, and the virtual controller unit operates the first simulation model and the second simulation model in accordance with the control command values ​​read from the memory.

[0010] A fourth aspect of the present invention is the simulation system of any one of the first to third aspects of the present invention, further comprising a display unit that displays a result of a simulation using the tentative simulation model.

[0011] A fifth aspect of the present invention is the simulation system of any one of the first to fourth aspects of the present invention, further comprising a parameter correction unit that corrects parameters set in the control software. [Effects of the Invention]

[0012] According to the first to fifth aspects of the present invention, even if the control specifications of the actual device are unknown, the appropriateness of the control command values ​​output in accordance with the control software can be evaluated based on a virtual simulation model, thereby enabling debugging of the control software without operating the actual device.

[0013] In particular, according to the second aspect of the present invention, the real device and the provisional simulation model are operated based on control command values ​​stored in a common memory, thereby enabling accurate simulation using the provisional simulation model.

[0014] In particular, according to the third aspect of the present invention, for a first unit whose control specifications are known, the control software can be debugged using a first simulation model created based on the actual specifications, and for a second unit whose control specifications are unknown, the control software can be debugged using a second simulation model created based on a provisional use.

[0015] In particular, according to the fourth aspect of the present invention, it is possible to visually check whether the results of a simulation using a provisional simulation model are appropriate.

[0016] In particular, according to the fifth aspect of the present invention, when the results of a simulation using a provisional simulation model are determined to be inappropriate, the parameters set in the control software can be corrected. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a block diagram showing a configuration of a simulation system. [Figure 2] 10 is a flowchart showing a debugging procedure. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0019] <1. Simulation system configuration> 1 is a block diagram showing the configuration of a simulation system 1 according to one embodiment of the present invention. This simulation system 1 is a system that simulates the operation of a real device 100 on a computer 2 in order to debug control software S that controls the real device 100. The real device 100 is, for example, industrial machinery such as a semiconductor manufacturing device, a display manufacturing device, a film forming device, or a digital printing machine. However, the real device 100 may also be a device other than those described above.

[0020] As shown in FIG. 1, the simulation system 1 includes a control command value output unit 10, a parameter correction unit 20, a memory 30, a real controller unit 40, a simulator 50, a virtual controller unit 60, and a display unit .

[0021] The control command value output unit 10 is a processing unit that outputs a control command value V in accordance with control software S installed in the computer 2. The control command value V is a command value used to control the real device 100. For example, if the part to be controlled by the real device 100 is a robot, the control command value V is a value that indicates the coordinates of the start and end points of the robot's movement, the robot's rotation angle, etc.

[0022] A plurality of parameters P are set in the control software S. The control software S outputs a control command value V according to the parameters P. Therefore, if an inappropriate parameter P is set in the control software S, the control command value V output from the control software S will also be an inappropriate value.

[0023] The parameter modification unit 20 is a processing unit that modifies the parameters P set in the control software S. The parameter modification unit 20 modifies the parameters P of the control software S in accordance with values ​​input by the user to the computer 2 from an operation unit 80 such as a keyboard or a mouse.

[0024] The memory 30 is a storage medium that stores the control command value V. The control command value V output from the control command value output unit 10 is written to the memory 30. The memory 30 is also communicably connected to the real controller unit 40 and the virtual controller unit 60. The real controller unit 40 and the virtual controller unit 60 can read the control command value V stored in the memory 30.

[0025] The real controller unit 40 is a controller that controls the operation of the real device 100. The real controller unit 40 is, for example, a PLC (Programmable Logic Controller). The real controller unit 40 reads a control command value V from the memory 30 and controls the operation of the real device 100 in accordance with the control command value V.

[0026] The simulator 50 is a processing unit that simulates the operation of the real device 100 on the computer 2. As shown in FIG. 1 , in this embodiment, the real device 100 has a first unit U1 and a second unit U2. Correspondingly, the simulator 50 has a first simulation model M1 that simulates the operation of the first unit U1 and a second simulation model M2 that simulates the operation of the second unit U2. Each simulation model M1 is created by simulation software installed on the computer 2.

[0027] It is assumed that the control specifications of the first unit U1 by the actual controller unit 40 are known. In this case, the first simulation model M1 is created based on the known control specifications of the actual controller unit 40. The control specifications are, for example, specifications of the interface between the actual controller unit 40 and the first unit U1.

[0028] On the other hand, it is assumed that the control specifications of the second unit U2 by the actual controller unit 40 are unknown. In this case, the second simulation model M2 is created based on provisional specifications that differ from the control specifications of the actual controller unit 40 (hereinafter referred to as "actual specifications"). The second simulation model M2 is an example of a "provisional simulation model" in the present invention. Since the actual specifications are unknown, the second simulation model M2 is created by the user of the simulation system 1 defining provisional specifications that can reproduce the operation of the second unit U2 based on the control command value V.

[0029] The virtual controller unit 60 is a controller that operates the simulator 50. The virtual controller unit 60 is realized by the CPU of the computer 2 operating in accordance with a program installed in the computer 2. The virtual controller unit 60 reads a control command value V from the memory 30, and operates the first simulation model M1 and the second simulation model M2 in accordance with the control command value V.

[0030] The display unit 70 is a device that displays the results of the simulation performed by the simulator 50. For example, a liquid crystal display is used for the display unit 70. The display unit 70 is electrically connected to the computer 2. The simulator 50 displays the results of the simulation performed by the first simulation model M1 and the results of the simulation performed by the second simulation model M2 on the display unit 70. Specifically, the simulator 50 operates a target part in a three-dimensional model corresponding to the actual device 100 based on the results of the simulation. The display unit 70 displays the movement of the three-dimensional model on a screen.

[0031] <2. Debugging control software> Next, we will explain the debugging of the control software S using the above-mentioned simulation system 1. Fig. 2 is a flowchart showing the debugging procedure.

[0032] 2, when debugging the control software S, first, the control command value output unit 10 outputs a control command value V in accordance with the control software S in which a certain parameter P is set (step S1). Here, the control command value V includes a control command value V for the first unit U1 and a control command value V for the second unit U2. The control command value V output from the control command value output unit 10 is stored in the memory 30.

[0033] Next, the virtual controller unit 60 reads the control command value V from the memory 30. Then, the virtual controller unit 60 operates the simulator 50 based on the control command value V (step S2). Specifically, the virtual controller unit 60 operates the first simulation model M1 based on the control command value V for the first unit U1. Furthermore, the virtual controller unit 60 operates the second simulation model M2 based on the control command value V for the second unit U2.

[0034] The simulator 50 displays the results of the simulation using the first simulation model M1 and the results of the simulation using the second simulation model M2 on the display unit 70 (step S3).

[0035] The user visually checks the simulation results displayed on the display unit 70. Then, the user determines whether the simulation results using the first simulation model M1 and the simulation results using the second simulation model M2 are appropriate (step S4). For example, if the three-dimensional model displayed on the display unit 70 shows that the robot interferes with other components when moving, or if the robot is not stopped in the correct position, the user determines that the simulation results are inappropriate.

[0036] If the result of the simulation is inappropriate (step S4: No), the user modifies the parameters P of the control software S (step S5). For example, if the result of the simulation using the first simulation model M1 is inappropriate, the user modifies the parameters P related to the first unit U1 of the control software S. Also, if the result of the simulation using the second simulation model M2 is inappropriate, the user modifies the parameters P related to the second unit U2 of the control software S.

[0037] Specifically, the user operates the operation unit 80 to input a corrected value for the parameter P of the control software S. Here, the user inputs a parameter P that is increased or decreased from the existing parameter P based on the results of the simulation. In response to this, the parameter correction unit 20 of the computer 2 corrects the parameter P of the control software S to the input value.

[0038] After correcting the parameter P of the control software S, the process returns to step S1 and executes the processes of steps S1 to S4 again. Then, the processes of steps S1 to S5 are repeated until the simulation result is judged to be appropriate in step S4. When the user eventually judges the simulation result to be appropriate in step S4 (step S4: Yes), debugging of the control software S is terminated.

[0039] As described above, in this simulation system 1, simulation models M1 and M2 corresponding to units U1 and U2 of the real device 100 are created, and the control software S is debugged based on the results of simulations using the simulation models M1 and M2.

[0040] In particular, in the case of a unit with unknown control specifications, such as the second unit U2, the simulation system 1 outputs simulation results using a provisional simulation model created using provisional specifications that differ from the actual specifications. Conventionally, simulation results could not be obtained for units with unknown control specifications. Furthermore, when evaluating the control of a unit with unknown control specifications, it was only confirmed that some control command value V was output from the control software S. In contrast, the simulation system 1 of this embodiment can evaluate whether the control command value V written to the memory 30 by the control software S is appropriate for the second unit U2 with unknown control specifications.

[0041] Therefore, by using this simulation system 1, even if the control specifications are unknown, it is possible to debug the control software S before manufacturing the actual device 100. Therefore, it is possible to optimize the parameters P of the control software S before manufacturing the actual device 100.

[0042] <3. Modifications> Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment.

[0043] In the above embodiment, the real device 100 has two units U1 and U2. However, the number of units that the real device 100 has may be one, or may be three or more.

[0044] In the above embodiment, the simulation results output from the simulator 50 are based on a three-dimensional model. However, the simulation results output from the simulator 50 may be based on a two-dimensional model or information such as numerical values.

[0045] In the above embodiment, a human user visually judges whether the simulation results displayed on the display unit 70 are appropriate. However, the simulator 50 may automatically output an alarm if the simulation results are inappropriate. For example, if the robot interferes with another component in the simulation model, the simulator 50 may display a warning message on the display unit 70 or output a warning sound.

[0046] In the above embodiment, the control command value output unit 10, the memory 30, and the virtual controller unit 60 are provided in one computer 2. However, some of these may be provided in another computer connected via a network.

[0047] Furthermore, some of the elements appearing in the above-described embodiments and modifications may be omitted, or other elements may be added, without departing from the spirit of the present invention. [Explanation of symbols]

[0048] 1: Simulation system 2: Computer 10: Control command value output section 20: Parameter modification section 30: Memory 40: Actual controller part 50: Simulator 60: Virtual controller section 70:Display section 80: Operation section 100: Actual device M1: First simulation model M2: Second simulation model P: Parameter S: Control software U1: First unit U2: Second Unit V: Control command value

Claims

1. A computer-based simulation system, a virtual simulation model that simulates the operation of the real device on a computer using virtual specifications that are different from the control specifications of the real device; a control command value output unit that outputs a control command value used to control the real device in accordance with control software installed on a computer; a memory for storing the control command value; a virtual controller unit that operates the virtual simulation model in accordance with the control command value read from the memory; A simulation system comprising:

2. 2. The simulation system according to claim 1, a real controller section that controls the real device in accordance with the control command value read from the memory; The simulation system further comprises:

3. 3. The simulation system according to claim 1, The real device is a first unit whose control specifications are known; The second unit, whose control specifications are unknown, Including, The simulation system includes: a first simulation model that simulates the operation of the first unit on a computer according to the control specifications of the first unit; a second simulation model that is the provisional simulation model that simulates the operation of the second unit on a computer according to provisional specifications that are different from the control specifications of the second unit; a simulator having The virtual controller unit operates the first simulation model and the second simulation model in accordance with the control command value read from the memory.

4. 3. The simulation system according to claim 1, a display unit for displaying the results of a simulation using the virtual simulation model; The simulation system further comprises:

5. 3. The simulation system according to claim 1, a parameter modification unit that modifies parameters set in the control software; The simulation system further comprises:

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