Industrial Machine Control Systems

Abstract

The present invention reproduces the state of a real device more accurately by using operation state data indicating the behavior of the real device.　This industrial machine control system comprises: a real device comprising a control device for controlling an industrial machine; and a digital device for simulating the real device by software. The digital device comprises an input unit that inputs operation state data acquired by the real device to the digital device, and simulates the real device by the digital device using the operation state data input by the input unit.

Description

[Technical field]

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

[0002] Digital simulators have been developed that model real equipment consisting of industrial machinery and the control devices and drive devices such as motors and amplifiers that control and operate the machinery, based on theoretical values ​​of each of the above industrial machinery, control devices, drive devices, etc. Moreover, the digital simulator generally has a structure in which each individual device is reproduced in software. In this regard, there is known a technology that can provide high-quality engineering by creating and debugging software that operates a control device that controls a field device installed in a plant, having a cloud that simulates the operating state of the control device according to simulated input or input to the control device and the software, and debugging the software based on the operation result of the simulation and output or simulated input from the control device. For example, see Patent Document 1. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-52812 A Summary of the Invention [Problem to be solved by the invention]

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

[0005] Therefore, it is desirable to reproduce the state of a real device more accurately by using operation state data that indicates the behavior of the real device. [Means for solving the problem]

[0006] One aspect of the industrial machinery control system disclosed herein is an industrial machinery control system consisting of a real device including a control device that controls industrial machinery, and a digital device that imitates the real device using software, wherein the digital device has an input unit that inputs operating status data acquired in the real device to the digital device, and the real device is imitated by the digital device using the operating status data input to the input unit. Effect of the Invention

[0007] According to one aspect, the operational state data indicative of the behavior of the real device can be used to more accurately recreate the state of the real device. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a functional block diagram illustrating an example of a functional configuration of an industrial machine control system according to an embodiment. [Diagram 2] FIG. 13 is a diagram showing an example of the operation of an industrial machinery control system when the operation of a ladder control device is reproduced using an actual signal processing speed. [Figure 3A] FIG. 4 is a diagram showing an example of an instruction in a ladder program. [Figure 3B] FIG. 3B is a diagram showing an example of a timing diagram of the instructions of FIG. 3A. [Figure 4] 11 is a diagram showing an example of the operation of the industrial machine control system when the operation of a machine tool is reproduced using an actual feedback amount. FIG. [Diagram 5]11 is a diagram showing an example of the operation of the industrial machine control system when the operation of a machine tool is reproduced using an actual feedback amount. FIG. [Figure 6] 11 is a diagram illustrating an example of the operation of the industrial machine control system when a machining program is corrected according to the CPU performance of an actual numerical control device. FIG. [Figure 7] FIG. 13 is a diagram showing an example of a test machining program for measuring BPTmin. [Figure 8] FIG. 13 is a diagram illustrating an example of the relationship between block length and BPT. [Figure 9] 11 is a diagram showing an example of adding or deleting a command point of a machining program by a simulation executing unit; FIG. [Figure 10] 11 is a diagram showing an example of the operation of the industrial machine control system when a machining program is corrected based on the actual power consumption of a machine tool. FIG. [Figure 11] FIG. 11 is a diagram showing an example of the relationship between feed speed (or spindle rotation speed) and power consumption. [Figure 12] FIG. 11 is a diagram showing an example of the relationship between the feed rate (or the spindle rotation speed) and the total power consumption. [Figure 13] 11 is a diagram showing an example of the operation of the industrial machinery control system when reproducing the occurrence of an overheat alarm using the motor temperature of a machine tool. FIG. [Figure 14] FIG. 11 is a diagram showing an example of the relationship between the rotation time and the motor temperature for each rotation speed (or current). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] <One embodiment> 1 is a functional block diagram showing an example of the functional configuration of an industrial machine control system according to an embodiment. Here, a machine tool is shown as an example of an industrial machine, and a numerical control device is shown as an example of a control device. Note that the present invention is not limited to machine tools and numerical control devices, and can also be applied to industrial machines such as injection molding machines, industrial robots, and service robots, as well as robot control devices that control industrial robots, etc. 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). 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 via 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 driving device 12, a peripheral device 13, and an information collection device 14. The machine tool 10 operates based on operation commands from the numerical control device 11, which will be described later. It should be noted that the numerical control device 11, the driving device 12, the peripheral device 13, and the information collecting device 14 are each included in the machine tool 10, but may be devices separate from the machine tool 10.

[0011] Numerical control device 11 is a numerical control device known to those skilled in the art, and generates operation commands based on a machining program acquired from, for example, a CAD / CAM device (not shown) or the like, and transmits the generated operation commands to machine tool 10. In this way, numerical control device 11 controls the operation of machine tool 10. Note that when machine tool 10 is a robot or the like, 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 relating to the signal processing speed and the processing capacity of the CPU, and information such as the amount of power, as operation status data R to an information collection device 14 described later.

[0012] Drive device 12 drives a motor (not shown) for a spindle included in machine tool 10 via an amplifier (not shown) included in drive device 12 based on a command from numerical control device 11. Specifically, drive device 12 drives a motor (not shown) while feeding back, as a signal, information including the position and speed of the motor (not shown) detected by an encoder (not shown). The motor (not shown) can be applied to various motors used in the feed shaft or spindle of a machine tool, or the arms of industrial machines and industrial robots. While driving an amplifier and motor (not shown), the driving device 12 outputs information regarding the behavior of the motor and machine (not shown) (for example, speed, motor temperature, etc.) as operating status data R to an information collecting device 14 (described later).

[0013] The peripheral device 13 is a belt conveyor or the like, and operates based on commands from the numerical control device 11. While the peripheral device 13 is operating, it outputs information about the surrounding environment, such as temperature, as operating status data R to an information collecting device 14, which will be described later.

[0014] The information collecting device 14 is, for example, a computer or the like, and includes an operation status data R acquiring unit 141. The information collecting device 14 includes a processor such as a CPU. The information collecting device 14 also includes a main memory device such as an auxiliary storage device, such as a hard disk drive (HDD) that stores various control programs such as application software and an operating system (OS), and a random access memory (RAM) for storing data temporarily required for the processor to execute a program. In the information collecting device 14, the arithmetic processing device reads the application software and the OS from the auxiliary storage device, and performs arithmetic processing based on the application software and the OS while expanding the read application software and the OS in the main storage device. Also, based on the results of this calculation, various pieces of hardware provided in the information collecting device 14 are controlled. In this way, the functional blocks of this embodiment are realized. In other words, this embodiment can be realized by the cooperation of hardware and software.

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

[0016] In the industrial machine control system 1 according to the present embodiment, the information collection device 14 is disposed in the machine tool 10, but it may be disposed 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. The control unit 22 also includes a simulation execution unit 220. The simulation execution unit 220 also includes an operation state data difference generation unit 221.

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

[0019] The storage unit 23 is a RAM, a HDD, or the like, and stores the operation status data R, the operation status difference data 231, and the operation status data D. The operating status data R is the operating status data R of the numerical control device 11, the driving device 12 and the peripheral device 13 of the machine tool 10 acquired by the information collection device 14 of the machine tool 10, as described above. The operating status difference data 231 is data obtained by subtracting the operating status data R of each of the numerical control device 11, the driving device 12 and the peripheral device 13 from the operating status data D of each of the numerical control device 11, the driving device 12 and the peripheral device 13 simulated by the simulation execution unit 220 described later, by the operating status data difference generation unit 221 described later. The operation status data D is operation status data D of the numerical control device 11, the driving device 12, and the peripheral device 13, which are simulated (simulated) by a 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, and the like, which are configured to be able to communicate 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 application program stored in the ROM via the bus, and controls the entire digital device 20 according to the system program and application program. As a result, as shown in FIG. 1, the control unit 22 is configured to realize the function of a simulation execution unit 220. The simulation execution unit 220 is also configured to realize the function of an 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 backed up by a battery (not shown), and is configured as a non-volatile memory that retains its memory state even when the power supply of the digital device 20 is turned off.

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

[0022] The operation status data difference generating unit 221 calculates the difference between the operation status data R and the operation status data D for each of the numerical control device 11, the drive device 12, and the peripheral device 13, and generates operation status difference data 231. The operation status data difference generating unit 221 stores the generated operation status difference data 231 for 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 this embodiment, the operating status data difference generation unit 221 is disposed in the digital device 20, but it may be disposed in the information collection device 14 of the machine tool 10, or may be disposed in both the information collection device 14 and the digital device 20. When the operating status data difference generation unit 221 is disposed in the information collection device 14, the digital device 20 may output the operating status data D of each of the numerical control device 11, the driving 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, the operation of the industrial machinery control system 1 will be described in the following cases: (A) when the operation of the machine tool 10 is reproduced using the actual signal processing speed, (B) when the operation of the machine tool 10 is reproduced using the actual feedback amount, (C) when the machining program is modified according to the actual CPU performance of the numerical control device 11, (D) when the machining program is modified based on the actual power consumption of the machine tool 10, and (E) when the occurrence of an overheat alarm is reproduced using the motor temperature of the machine tool 10.

[0024] (A) Reproducing the behavior of a ladder controller using actual signal processing speed FIG. 2 is a diagram showing an example of the operation of the industrial machine control system 1 when the operation of the ladder control device is reproduced using an actual signal processing speed. 2, a numerical control device 11 of a machine tool 10 implements and executes a ladder program in the machine tool 10, for example, in a ladder control device (not shown) connected to the numerical control device 11. The numerical control device 11 measures a signal processing speed while controlling the machine tool 10, and outputs information on the measured signal processing speed to an information collecting device 14 as operation status data R. The information collecting device 14 outputs the operation status data R of the numerical control device 11 to a digital device 20. Based on the signal processing speed included in the operation status data R acquired from the machine tool 10, the digital device 20 adjusts the signal processing speed to the same as that when implemented in the machine tool 10, and simulates the ladder program.

[0025] Specifically, when a ladder controller (not shown) executes each instruction of a ladder program, the numerical control device 11 measures the processing time of each instruction as a signal processing speed. Fig. 3A is a diagram showing an example of an instruction of a 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 also measured for other instructions in the same manner as in Fig. 3A. For example, when a ladder controller (not shown) executes a command to write data to the numerical controller 11 shown in Fig. 3A, the numerical controller 11 measures the time t from time t1 when the ladder controller (not shown) outputs an ACT signal for command execution to time t3 when the ladder controller (not shown) internally completes processing of the functional command as the processing time of the command. Note that the time from time t4 to time t6 when the completion signal W1 is returned is the next or subsequent ladder execution period, so the numerical controller 11 can obtain the accurate processing time of the ladder controller (not shown) by measuring the time t from time t1 to time t3. The numerical control device 11 inputs the processing times of all commands included in the ladder program to the digital device 20 via the information collecting device 14 as the signal processing speed of the operation status data R.

[0026] The digital device 20 corrects the processing time of the instructions of the ladder program in the digital device 20 to match the input processing time. This enables the digital device 20 to execute the ladder program at the same timing as the machine tool 10. In other words, in the past, while a simulator could reproduce logic, it was not able to reproduce the actual processing speed (response speed), which sometimes caused problems with signal timing during implementation. However, digital device 20 makes it possible to accurately reproduce the signal processing speed by inputting the signal processing speed into digital device 20.

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

[0028] The information collecting device 14 acquires a position command, a speed command, a current command, as well as a position feedback, a speed feedback, and a current feedback from the numerical control device 11 as operation status data R. The information collecting device 14 outputs the acquired operation status 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 operating state data R and the machining program. Specifically, the simulation execution unit 220 operates a drive unit model M1 which models the drive unit 12, a motor model M2 which models the motor MO, and a machine model M3 which models the machine MA based on a machining program, for example, and calculates the feedback amounts of current feedback from the drive unit model M1, velocity 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, velocity 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, velocity feedback, and position feedback, and inputs the difference between the feedback amounts of each feedback, thereby simulating the position control, velocity control, and current control. In this way, although it was difficult for the digital device 20 to accurately match the actual motor behavior or machine behavior with conventional simulators, accurate reproduction is possible by inputting the difference in feedback between the machine tool 10 and the digital device 20 into the digital device 20.

[0030] The drive model M1 and the motor model M2 are created using a known method such as, for example, International Publication No. 2020 / 003738. The machine model M3 is created using a known method such as, for example, “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, Journal of the Japan Society for Precision Engineering, etc.

[0031] 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 this is not limited to this. 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, which are included in the operating state data R acquired by the machine tool 10, to the digital device 20. Fig. 5 is a diagram showing an example of the operation of the industrial machine control system when the operation of the machine tool 10 is reproduced using the actual feedback amount. Elements having the same functions as those in Fig. 4 are given the same reference numerals and detailed explanations are omitted. In addition, in the digital device 20, the motor model M2 and the machine model M3 are omitted. In this way, while it was difficult for conventional simulators to accurately match the behavior of an actual motor or machine, the industrial machinery control system 1 makes it possible to more accurately reproduce this by inputting the feedback amount of the machine tool 10 into the digital device 20.

[0032] (C) When modifying the machining program according to the CPU performance of the actual numerical control device 11 Fig. 6 is a diagram showing an example of the operation of the industrial machinery control system 1 when correcting a machining program according to the CPU performance of the actual numerical control device 11. Elements having the same functions as those in Fig. 4 are given the same reference numerals, and detailed description thereof will be omitted. As shown in Fig. 6, the numerical control device 11 measures BPTmin, which is the limit (minimum) of the command processing speed (for example, BPT: Block Processing Time) of the numerical control device 11, as described below. The digital device 20 acquires information indicating the relationship between the block length of the machining program in the numerical control device 11 and the BPT, and operation status data R including BPTmin via the information collection device 14, and matches it with the BPTmin of the numerical control device 11 in a simulation. The digital device 20 executes a simulation, judges the margin based on whether BPTmin is reached, and modifies the machining program to correspond to the BPTmin of the numerical control device 11 by adding / deleting command points of the machining program.

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

[0034] The information collecting device 14 outputs to the digital device 20 the operation status data R including the relationship (function) of block length-BPT in FIG.

[0035] The simulation execution unit 220 of the digital device 20 matches the BPTmin when executing the machining program in the simulation to the BPTmin included in the operation state data R. In other words, the simulation of the digital device 20 has a smaller BPT limit value (the program can be processed more finely and faster), but the BPTmin is matched to that of the machine tool 10. The simulation execution unit 220 then determines whether or not the command feed speed is achieved (i.e., whether or not deceleration occurs) when the machining program is run in the simulation, and modifies the machining program by adding or deleting command points according to the determination result. For example, if the commanded feed speed is achieved (does not decelerate), the simulation execution unit 220 adds a command point to the machining program (shortens the block length), and if the commanded feed speed is not achieved (decelerates), it deletes a command point from the machining program (increases the block length).

[0036] FIG. 9 is a diagram showing an example of adding or deleting a command point of a machining program by the simulation executing unit 220. In FIG. As shown in the lower part of FIG. 9, when the commanded feedrate is not achieved (the feedrate is decreased), the simulation execution unit 220 deletes the commanded point from the machining program, that is, increases the block length, so that the commanded feedrate is achieved. On the other hand, for example, if the command feed rate is obtained with a block length of 0.1 mm in the original machining program, the simulation execution unit 220 changes the block length to 0.05 mm, 0.01 mm, etc., i.e., performs a simulation again with a machining program with a command point added. If the speed does not decrease when the block length is 0.05 mm but decreases when it is 0.01 mm, the simulation execution unit 220 modifies the machining program by adding a command point so that the block length becomes 0.05 mm, as shown in the upper part of Fig. 9. The digital device 20 transmits the modified machining program to the machine tool 10 . As a result, while conventional simulators did not take into account the actual numerical control processing capacity, by inputting the command processing capacity (BPT processing capacity) of the numerical control device 11 into the digital device 20, it is possible to optimize the machining program according to the command processing capacity of the numerical control device 11.

[0037] (D) About the case where the machining program is corrected based on the actual power consumption of the machine tool 10 Fig. 10 is a diagram showing an example of the operation of industrial machine control system 1 when correcting a machining program based on the actual power consumption of machine tool 10. Elements having the same functions as those in Fig. 4 are given the same reference numerals and detailed explanations are omitted. Also, Fig. 10 omits illustration of current feedback of drive device 12, speed feedback of motor MO, and position feedback of machine MA. As described below, the numerical control device 11 measures the power consumption (instantaneous value for each speed) of the machine tool 10 according to the feed speed or spindle speed, and obtains the relationship (function) between the feed speed or spindle speed and the power consumption. The digital device 20 obtains the operation state data R including the relationship (function) between the speed or spindle speed and the power consumption measured by the numerical control device 11 via the information collection device 14. In the simulation to be executed, the digital device 20 calculates the total power consumption of the machine tool 10 by integrating the power consumption during the operation of the machining program using the obtained relationship (function) between the speed or spindle speed and the power consumption as a drive device power model M4. The digital device 20 corrects the feed speed or spindle speed of the machining program that minimizes the total power consumption including the machining time.

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

[0039] In the simulation that it executes, the simulation execution unit 220 of the digital device 20 uses the feed speed (or spindle rotation speed)-power consumption relationship (function) contained in the operating state data R as a drive unit power model M4, and calculates and adds up the instantaneous power consumption when the machining program is run for each feed speed (or spindle rotation speed) in the simulation to calculate the total power consumption during operation. FIG. 12 is a diagram showing an example of the relationship between the feed speed (or the spindle rotation speed) and the total power consumption. 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 100Wh through simulation. Also, the simulation execution unit 220 calculates the total power consumption to be 80Wh, 40Wh, and 60Wh through 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 result, the simulation execution unit 220 modifies the machining program by changing the feed rate from F2000 [mm / min] to F1500 [mm / min] at which power consumption is minimized. The digital device 20 transmits the modified machining program to the machine tool 10 . In this way, the digital device 20 is able to accurately reproduce a power simulation, whereas in conventional simulators it was difficult to reproduce the actual amount of power using only a theoretical model, by inputting the power waveform measured by the machine tool 10 into the digital device 20.

[0040] (E) Reproducing the occurrence of an overheat alarm using the motor temperature of the machine tool 10 Fig. 13 is a diagram showing an example of the operation of industrial machinery control system 1 when reproducing the occurrence of an overheat alarm using the motor temperature of machine tool 10. Elements having the same functions as those in Fig. 4 are given the same reference numerals, and detailed description thereof will be omitted. 4, the numerical control device 11 executes the machining program to obtain position feedback, speed feedback, and current feedback as well as position commands, speed commands, and current commands as operation state data R. Furthermore, the numerical control device 11 also obtains information on how long the motor MO has been rotated, which indicates 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 on the motor MO, as operation state data R. The digital device 20 obtains the operation state data R in the numerical control device 11 via the information collection device 14, and simulates the occurrence of an overheat alarm by correcting the motor temperature in the motor model M2 using the relationship between the rotation speed (or current) of the motor MO, the operation time of the motor MO, and the motor temperature of the motor MO measured by the numerical control device 11.

[0041] Specifically, 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 test machining program that changes the rotation speed (or current), for example. 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 speed in the machining program, and the relationship between each rotation time and the motor temperature is measured. In Fig. 14, a threshold value for issuing an overheat alarm is preset.

[0042] The information collecting device 14 outputs to the digital device 20 the operating state data R including the rotation speed (or current) and rotation time of the motor MO acquired by the numerical control device 11 as well as the relationship (function) of rotation time-temperature in FIG.

[0043] The simulation execution unit 220 of the digital device 20 compares the motor temperature calculated from the relationship (function) between the rotation time and temperature included in the acquired operating state data R with the motor temperature calculated from the motor model M2, and corrects the motor temperature by inputting the difference. This enables the simulation execution unit 220 to accurately simulate (mimic) the occurrence of an overheat alarm. In other words, with conventional simulators, it was difficult for the digital device 20 to reproduce the actual motor temperature using only a theoretical model, but 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 is possible to reproduce an accurate temperature simulation, making it possible to perform preventive maintenance in the event of an overheating alarm for the motor MO.

[0044] In addition, the numerical control device 11 acquires information on how long the motor MO has been rotating, including the rotation speed (or current) of the motor MO and the rotation time of the motor MO, as well as the relationship (function) between rotation time and temperature in Figure 14, and the information collection device 14 outputs operating status data R including the information to the digital device 20, but this is not limited to the above. For example, the numerical control device 11 may simply measure the motor temperature T0 of the motor MO when stopped, and the motor temperature Tr1 and cutting speed F1 of the motor MO when cutting. The information collection device 14 outputs the motor temperature T0 of the motor MO when stopped, and the motor temperature Tr1 and cutting speed F1 of the motor MO when cutting, measured by the numerical control device 11, to the digital device 20. Note that, since the theoretical heat generation of the motor can be calculated from the motor current value and winding resistance, the theoretical temperature value for the motor temperature T0 of the motor MO when stopped is "0" degrees. Also, the theoretical temperature value for the motor temperature Tr1 of the motor MO when 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 distributes ΔT from speed 0 to cutting speed F1, and calculates the temperature T at actual speed F as theoretical temperature value Td1+T0+(ΔT / cutting speed F1)×actual speed F. It should be noted that the motor temperature T0 includes the ambient temperature, and the difference ΔT includes heat generated by loads due to mechanical friction and tool wear, and heat generated by individual differences in products due to variations in physical constants (resistance values), enabling the digital device 20 to perform a more accurate simulation and accurately simulate (mimic) the occurrence of an overheat alarm.

[0046] As described above, the industrial machinery control system 1 according to one embodiment can reproduce the state of the machine tool 10 more accurately than conventional simulators by inputting operating status data indicating the behavior of the machine tool 10 into the digital device 20. In addition, the industrial machinery control system 1 can perform a simulation one or more times using highly accurate information reproduced by the digital device 20, thereby allowing the control-related setting values ​​and control programs present in the machine tool 10 to be corrected accurately and in a short period of time.

[0047] Although one embodiment has been described above, the industrial machine control system 1 is not limited to the above-described embodiment, and may include modifications and improvements within the scope of achieving the object.

[0048] <Variation 1> In one embodiment, the machine tool 10 includes, but is not limited to, a numerical control device 11, a driving device 12, a peripheral device 13, and an information collecting device 14. For example, each of the numerical control device 11, the driving device 12, the peripheral device 13, and the information collecting device 14 may be a device different from the machine tool 10. The numerical control device 11 may also include a digital device 20 .

[0049] <Variation 2> Also, for example, in one embodiment, the digital device 20 performs preventive maintenance of an overheat alarm of the motor MO by comparing the measured motor temperature of the motor MO with the motor temperature of the simulated motor model M2 and inputting the difference into the digital device 20, but is not limited to this. For example, the operating status data R includes operating information such as the operating time, cutting time, spindle rotation speed, etc. of parts such as a ball screw, bearings, and spindle included in the machine tool 10, and the digital device 20 may simulate the replacement time of parts such as a ball screw by comparing the operating information included in the acquired operating status data R with operating information obtained by simulation and inputting the difference into the digital device 20.

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

[0051] The program can be stored and provided to the computer using various types of non-transitory computer readable media. The non-transitory computer readable media includes various types of tangible storage media. Examples of the 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-ROMs (Read Only Memory), CD-Rs, CD-R / Ws, and semiconductor memories (e.g., mask ROMs, PROMs (Programmable ROMs), EPROMs (Erasable PROMs), flash ROMs, and RAMs). The program may also be provided to the computer by various types of transitory computer readable media. Examples of the transitory computer readable media include electrical signals, optical signals, and electromagnetic waves. The transitory computer readable media can provide the program to the computer via wired communication paths such as electric wires and optical fibers, or wireless communication paths.

[0052] In addition, the steps of writing a program to be recorded on a recording medium include not only processes that are performed chronologically according to the order, but also processes that are not necessarily performed chronologically but are executed in parallel or individually.

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

[0054] (1) The industrial machinery control system 1 disclosed herein is an industrial machinery control system consisting of a real device including a numerical control device 11 that controls a machine tool 10, and a digital device 20 that imitates the real device by software, wherein the digital device 20 has an input unit 21 that inputs operating status data R acquired in the real device to the digital device 20, and the real device is imitated by the digital device 20 based on the operating status 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 by 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 status data may include difference data between the operation status data R of the real device and the operation status data D of the digital device 20. By doing so, the industrial machine control system 1 is able to perform more accurate reproduction.

[0056] (3) In the industrial machinery control system 1 described in (1), the operating status data may include at least one of operating status data R measured from a real device, detected operating status data R, or a control amount created within the real device. In this way, the industrial machine control system 1 can achieve the same effect as (2).

[0057] (4) In the industrial machine control system 1 described in (2), the digital device 20 may input difference data to correct a program executed in the real device or a parameter set in the real device. In this way, 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 described in any one of (1) to (4), the operation status data R may include at least any one of a signal processing speed, a feedback amount, a CPU performance, a power consumption, or a motor temperature. In this way, the industrial machinery control system 1 can accurately reproduce the real equipment depending on the situation.

[0059] (6) In the industrial machine control system 1 described in (5), when the operation status data R is a signal processing speed, the digital device 20 may reproduce the operation of the machine tool 10 using the processing time for each command included in the program. This enables the industrial machine control system 1 to execute the program at the same timing as the machine tool 10.

[0060] (7) In the industrial machinery control system 1 described in (5), when the operating status data R is a feedback amount, the digital device 20 may reproduce the operation of the machine tool 10 using at least one of the feedback amounts of position feedback, velocity feedback, or current feedback. In this way, the industrial machine control system 1 can be accurately adapted to the behavior of the motor of the actual machine tool 10 and the behavior of the machine itself.

[0061] (8) In the industrial machinery control system 1 described in (5), when the operating status data R is CPU performance, the digital device 20 may modify the program using information indicating the limit value of the command processing speed of the numerical control device 11 and the relationship between the block length of the program and the command processing speed. In this way, the industrial machine control system 1 can optimize the program taking into consideration the processing capacity of the actual numerical control device 11.

[0062] (9) In the industrial machinery control system 1 described in (5), when the operating status data R is power consumption, the digital device 20 may modify the program using the relationship between the feed speed or spindle rotation speed of the motor MO included in the machine tool 10 and the power consumption at that feed speed or spindle rotation speed. In this way, the industrial machine control system 1 can reproduce the power consumption of the machine tool 10 with high accuracy.

[0063] (10) In the industrial machinery control system 1 described in (5), when the operating status data R is motor temperature, the digital device 20 may reproduce the occurrence of an alarm regarding the motor MO 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. This enables the industrial machinery control system 1 to perform preventive maintenance of alarms 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 a modified program to the machine tool 10. In this way, the industrial machine control system 1 can optimize the program executed by the machine tool 10. [Explanation of symbols]

[0065] 1. Industrial Machine Control Systems 10 Machine tools 11 Numerical control device 12 Drive unit 13 Peripheral Devices 14 Information gathering device 20 Digital Devices 21 Input section 22 Control section 220 Simulation Execution Department 221 Operation status data difference generation unit 23 Memory section R Operation status data 231 Operation status differential data D Operational status 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 operational status data includes differential data between the operational status data of the real device and the operational status data of the digital device, at least one of measured operational status data from the real device, detected operational status data, or control variables created within the real device; imitating the real device with the digital device according to the operational status data input to the input unit; The digital device corrects a program executed in the real device or a parameter set in the real device by inputting the difference data, in the industrial machine control system.

2. 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.

3. 3. The industrial machine control system according to claim 2, 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.

4. 3. The industrial machine control system according to claim 2, 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.

5. 3. The industrial machinery control system according to claim 2, 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.

6. 3. The industrial machinery control system according to claim 2, 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.

7. 3. The industrial machinery control system according to claim 2, 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.

8. The industrial machine control system of claim 1 , wherein the digital device transmits a modified version of the program to the real device.

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