Simulation device

Abstract

The present invention makes it easy to acquire an image representing the state of an industrial machine, on the basis of only internal data of a control device and without providing any definition pertaining to the mechanical configuration of the industrial machine.　This simulation device is for an industrial machine driven and controlled by a control device, the simulation device comprising: a simulation unit that reproduces an operation of the control device and generates internal data of the control device; and an image output unit that acquires, from a database which stores in advance a plurality of pieces of internal data of an actual operation of the control device and images representing a state of the industrial machine for each of the plurality of pieces of internal data, an image representing a state of the industrial machine that corresponds to the generated internal data.

Description

Simulation Equipment

[0001] The present disclosure relates to a simulation device that reproduces the state of an industrial machine that is drive-controlled by a control device.

[0002] There is a demand for a function that reproduces the state of industrial machinery on a personal computer using a digital twin. For example, a machined surface quality simulation device that simulates the characteristics of the appearance of the machined surface of a workpiece machined by a machine tool that drives its axes according to a machining program is known. The device determines whether a predetermined machining error that characterizes the appearance occurs based on axis data, which is data about the axis operation, and calculates the machining error shape caused by the machining error based on the machining conditions and axis positions when the machine tool machines the workpiece, and then draws the calculated machining error shape. For example, see Patent Document 1.

[0003] International Publication No. 2023 / 188433

[0004] To reproduce the state of industrial machinery on a PC, it is necessary to define information such as the shape and operating range of the parts that make up the machine, as well as the correspondence with the internal data of the control device (coordinate values, I / O signals with the outside, etc.), which can be extremely difficult, especially when the machine configuration is complex.

[0005] Therefore, it is desirable to easily obtain an image showing the state of an industrial machine based only on the internal data of the control device, without defining the mechanical configuration of the industrial machine.

[0006] One aspect of the simulation device of the present disclosure is a simulation device for industrial machinery that is driven and controlled by a control device, and includes a simulation unit that reproduces the operation of the control device and generates internal data for the control device, and an image output unit that acquires and outputs an image representing the state of the industrial machinery corresponding to the generated internal data from a database that stores in advance multiple pieces of internal data in actual operations of the control device and images representing the state of the industrial machinery for each of the multiple internal data.

[0007] 1 is a diagram showing an example of a functional block configuration of a simulation system according to an embodiment; FIG. 2 is a diagram showing an example of internal data; FIG. 3 is a diagram showing an example of internal data; FIG. 4 is a diagram showing an example of an image stored in industrial machine image data; FIG. 5 is a diagram showing an example of an image stored in industrial machine image data; FIG. 6 is a diagram showing an example of an image stored in industrial machine image data; FIG. 7 is a diagram showing an example of internal data of a generated numerical control device; FIG. 8 is a diagram showing an example of a synthesized image; and FIG. 9 is a flowchart illustrating simulation processing of a simulation device.

[0008] A simulation system according to an embodiment will be described in detail below with reference to the drawings. FIG. 1 is a diagram illustrating an example of a functional block configuration of a simulation system according to an embodiment. Here, an example is illustrated in which internal data of a numerical control device (not shown) that controls a machine tool (not shown) as an industrial machine is used. The present invention can also be applied to a case in which internal data of a robot control device that controls a robot as an industrial machine is used. As shown in FIG. 1 , the simulation system 1 includes a simulation device 10 and a database 20. The simulation device 10 and the database 20 are connected to each other and communicate via a network (not shown), such as a local area network (LAN) or the Internet. In this case, the simulation device 10 and the database 20 include a communication unit (not shown) for communicating with each other via such a network. The simulation device 10 and the database 20 may also be directly connected to each other via a connection interface (not shown). Although the simulation device 10 is described as a separate device from the database 20, the simulation device 10 may include the database 20, as described below.

[0009] <Database 20> The database 20 is, for example, a data server or the like, and includes internal data 210 and industrial machine image data 220. The internal data 210 stores internal data of a numerical control device (not shown) that drives and controls a machine tool (not shown) acquired at predetermined time intervals by a machine tool manufacturer, a third party, or the like, by actually operating the machine tool. The internal data 210 includes at least one of the following: coordinate values ​​of the control axes of the machine tool, parameter values ​​of the numerical control device, diagnostic data values ​​of the numerical control device, modal data values ​​of the numerical control device, interface values ​​between the numerical control device and external devices (e.g., peripheral devices such as robots), interface values ​​between functions within the numerical control device, work memory values ​​within the numerical control device, and code of a machining program currently being executed by the numerical control device. The internal data 210 may also include sensor values, such as distance sensors and temperature sensors, arranged on the machine tool (not shown).

[0010] 2A and 2B are diagrams showing an example of internal data 210. As shown in FIG. 3C (described later), FIG. 2A shows internal data of a numerical control device (not shown) that drives and controls a machine tool together with a robot as a peripheral device. As shown in FIG. 3D (described later), FIG. 2B shows internal data of the numerical control device (not shown) when the robot of FIG. 3C removes a workpiece from the machine tool. The internal data 210 shown in FIGS. 2A and 2B includes information such as machine coordinate values ​​of control axes and tool positions on the machine tool, and sensor values ​​of sensors installed on the machine tool and robot, and has storage areas such as "internal data," "value," and "description." The "internal data" storage area in the internal data 210 stores internal data names such as "machine coordinate values," "modal," "distance sensor," "pressure sensor," and "temperature sensor." The "value" storage area in the internal data 210 stores the values ​​of the internal data stored in the "internal data" storage area. Note that in FIG. 2B, as described later, the pressure sensor value becomes higher than that in FIG. 2A when the robot of FIG. 3D removes a workpiece. The storage area "explanation" in the internal data stores an explanation of the meaning indicated by the value of the internal data stored in the storage area "internal data."

[0011] The predetermined time interval at which the internal data 210 is acquired may be set to a time interval (e.g., a range from several seconds to several minutes) depending on the operating status of the machine tool (not shown) (e.g., whether machining is in progress or not). Alternatively, the predetermined time interval may be set to the time interval of a sensor value measured by a distance sensor or the like (e.g., a few milliseconds). In other words, the internal data 210 may store the internal data of the numerical control device at short time intervals when the machine tool is operating and machining is in progress, and may store the internal data of the numerical control device at longer time intervals when the machine tool is not operating and not machining. Furthermore, it is preferable that the internal data 210 be stored for each model of machine tool and each model of numerical control device.

[0012] The industrial machine image data 220 stores images representing the state of a machine tool (not shown) captured by a machine tool manufacturer, a third party, or the like using a digital camera at the time the internal data 210 is acquired, in association with the internal data 210. FIGS. 3A to 3D are diagrams showing examples of images stored in the industrial machine image data 220. FIG. 3A shows an image representing the state of a three-axis machining center as a machine tool. FIG. 3B shows an image representing the state of the three-axis machining center of FIG. 3A when cutting a workpiece. FIG. 3C shows an image representing the state of the machine tool and a robot (peripheral device) that removes a workpiece machined by the machine tool. FIG. 3D shows an image representing the state of the robot (peripheral device) of FIG. 3C when removing a workpiece from the machine tool. The industrial machine image data 220 stores images including one or more of the state of the machine tool, the state of a robot (peripheral device) operating in cooperation with the machine tool, the state of the internal structure of the machine tool, and the state of a workpiece machined by the machine tool. Furthermore, it is preferable that the industrial machine image data 220 stores images for each model of machine tool and each model of numerical control device.

[0013] <Simulation Apparatus 10> The simulation apparatus 10 is, for example, a known information processing apparatus (computer) or the like, and as shown in FIG. 1 , includes a simulation unit 110 and an image output unit 120. The image output unit 120 includes an approximate image extraction unit 1201. The simulation apparatus 10 includes a calculation processing unit (not shown), such as a CPU, to realize the operations of the functional blocks in FIG. 1 . The simulation apparatus 10 also includes a main storage unit (not shown), such as an auxiliary storage unit (not shown), such as a ROM (Read Only Memory) or HDD (Hard Disk Drive) that stores various control programs, and a RAM (Random Access Memory) for storing data temporarily required for the calculation processing unit to execute the programs.

[0014] In the simulation device 10, the arithmetic processing unit reads the OS and application software from the auxiliary storage device, and executes arithmetic processing based on the OS and application software while loading the read OS and application software into the main storage device. Based on the results of this calculation, the simulation device 10 controls each piece of hardware. In this way, the processing by the functional blocks in Figure 1 is realized. In other words, the simulation device 10 can be realized by the cooperation of hardware and software.

[0015] The simulation unit 110 reproduces (simulates) the operation of a numerical control device (not shown) and generates internal data of the numerical control device (not shown). Specifically, the simulation unit 110 uses a known simulation method such as that described in Patent Document 1 to simulate the operation of the numerical control device (not shown) and the operation of the machine tool based on an actual machining program, etc., and generates internal data of the numerical control device as shown in Fig. 4. Note that, when the numerical control device (not shown) controls peripheral devices such as a robot as well as the machine tool, as shown in Figs. 3C and 3D, the simulation unit 110 may simulate the operation of the numerical control device (not shown) and the operations of the peripheral devices such as the machine tool and the robot based on a robot program as well as a machining program.

[0016] The image output unit 120 has an approximate image extraction unit 1201, and acquires and outputs an image representing the state of the machine tool corresponding to the generated internal data from a database 20 that stores in advance multiple pieces of internal data 210 in the actual operation of the numerical control device and industrial machine image data 220 representing the state of the machine tool for each of the multiple pieces of internal data 210.

[0017] The similar image extraction unit 1201 extracts from the database 20 internal data 210 that is similar to the generated internal data within a predetermined range, and an image representing the state of the machine tool corresponding to the similar internal data 210. Specifically, for example, as shown in FIGS. 3C and 3D , when a numerical control device (not shown) drives and controls a machine tool and a robot (peripheral device), the similar image extraction unit 1201 extracts from the database 20 the internal data 210 of FIGS. 2A and 2B as internal data that is similar to the internal data of FIG. 4 within a predetermined range, and the corresponding images of FIGS. 3C and 3D . Here, the predetermined range is a range that is set in advance based on values ​​in the internal data generated by the simulation unit 110, such as machine coordinate values ​​and sensor values. Alternatively, the predetermined range may be determined based on whether or not the range matches the modality of the internal data generated by the simulation unit 110.

[0018] Since the pressure sensor value of the internal data 210 of FIG. 2A extracted by the approximate image extraction unit 1201 is closer to the value of the internal data of FIG. 4 than the pressure sensor value of the internal data 210 of FIG. 2B, the image output unit 120 selects the image of FIG. 3C as the image representing the state of the machine tool corresponding to the internal data of FIG. 4. The image output unit 120 generates an image (display screen) by combining the selected image with the internal data of FIG. 4, and displays the combined image on a display device (not shown), such as a liquid crystal display, included in the simulation device 10. FIG. 5 is a diagram showing an example of the combined image. As shown in FIG. 5, the combined image has an image of a display device displaying the internal data of FIG. 4 on the left side. The combined image also has the image of FIG. 3C on the upper right and an image of the inside of the machine tool on the lower right. In this way, the simulation device 10 can easily obtain an image representing the state of the machine tool based only on the internal data of the numerical control device, without defining the mechanical configuration of the machine tool.

[0019] <Simulation Processing of Simulation Apparatus 10> Next, the flow of the simulation processing of the simulation apparatus 10 will be described with reference to Fig. 6. Fig. 6 is a flowchart illustrating the simulation processing of the simulation apparatus 10.

[0020] In step S11, the simulation unit 110 simulates the operation of a numerical control device (not shown) as well as the operation of the machine tool (and peripheral devices such as a robot), and generates internal data for the numerical control device.

[0021] In step S12, the similar image extraction unit 1201 extracts from the database 20 internal data 210 that is similar within a predetermined range to the internal data generated in step S11, and an image representing the state of the machine tool corresponding to the similar internal data 210.

[0022] In step S13, the image output unit 120 selects an image of the internal data 210 extracted in step S12 that is closest to the value of the internal data generated in step S11 as an image representing the state of the machine tool.

[0023] In step S14, the image output unit 120 combines the internal data generated in step S11 with the image selected in step S13, and outputs the combined image to a display device (not shown) of the simulation device 10.

[0024] In step S15, the simulation unit 110 determines whether the simulation has ended. If the simulation has not ended, the process returns to step S11. If the simulation has ended, the simulation process of the simulation device 10 ends.

[0025] As described above, the simulation system 1 according to one embodiment can easily obtain an image representing the state of an industrial machine based only on the internal data of the control device, without defining the mechanical configuration of the industrial machine.

[0026] <Modification 1> In the embodiment described above, the simulation device 10 and the database 20 are different devices, but this is not limiting. For example, the simulation device 10 may include the database 20. Furthermore, although there is one database 20, this is not limiting, and a database 20 may be prepared for each machine tool manufacturer, third party, etc.

[0027] <Modification 2> Also, for example, in the above-described embodiment, the image output unit 120 selected an image of the internal data 210 that is closest to the internal data generated by the simulation unit 110 from among the images representing the state of the machine tool extracted by the similar image extraction unit 1201, but this is not limited to this. For example, the simulation device 10 may generate a prompt based on the internal data generated by the simulation unit 110 and images of the internal data 210 and industrial machine image data 220 that are similar to the internal data within a predetermined range, and input the generated prompt to an external image generation AI device, thereby acquiring an image representing the state of the machine tool.

[0028] In one embodiment, each function included in the simulation system 1 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.

[0029] The program can be stored and supplied to a computer using various types of non-transitory computer-readable media. 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-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 be provided to the computer by various types of transient computer-readable media. Examples of transient computer-readable media include electrical signals, optical signals, and electromagnetic waves. The transient computer-readable media can provide the program to the computer via a wired communication path such as an electrical wire or optical fiber, or via a wireless communication path.

[0030] The step of executing the program recorded on the recording medium includes not only processes that are performed in chronological order, but also processes that are not necessarily performed in chronological order but are performed in parallel or individually. Also, the step of writing the program may be performed by cloud computing.

[0031] Although the present disclosure has been described in detail, the present disclosure is not limited to the individual embodiments described above. Various additions, substitutions, modifications, partial deletions, etc. are possible in these embodiments without departing from the gist of the present disclosure or the spirit of the present disclosure derived from the content of the claims and their equivalents. These embodiments can also be implemented in combination. For example, in the above-described embodiments, the order of each operation and the order of each process are shown as examples and are not limited to these. The same applies when numerical values ​​or mathematical expressions are used in the description of the above-described embodiments.

[0032] The following supplementary notes are further disclosed regarding the above-described embodiments and modifications. (Supplementary Note 1) A simulation device (10) is a simulation device for an industrial machine driven and controlled by a control device, and includes a simulation unit (110) that reproduces the operation of the control device and generates internal data of the control device, and an image output unit (120) that acquires and outputs an image representing the state of the industrial machine corresponding to the generated internal data from a database (20) that stores in advance a plurality of pieces of internal data (210) representing actual operations of the control device and an image (220) representing the state of the industrial machine for each of the plurality of pieces of internal data (210). (Supplementary Note 2) In the simulation device (10) of Supplementary Note 1, the image output unit (120) includes an approximate image extraction unit (1201) that extracts, from the database (20), internal data (210) that is similar to the generated internal data within a predetermined range and an image (220) representing the state of the industrial machine that corresponds to the similar internal data (210). (Supplementary Note 3) In the simulation device (10) of Supplementary Note 2, the image output unit (120) outputs an image obtained by combining the generated internal data with the image extracted by the approximate image extraction unit (1201). (Supplementary Note 4) In the simulation device (10) of any of Supplements 1 to 3, the internal data of the control device includes one or more of coordinate values ​​of the control axis, parameter values ​​of the control device, values ​​of diagnostic data of the control device, values ​​of modal data of the control device, values ​​of an interface between the control device and an external device, values ​​of an interface between functions in the control device, values ​​of a work memory in the control device, and program code being executed in the control device. (Supplementary Note 5) In the simulation device (10) of any of Supplements 1 to 3, the image representing the state of the industrial machine stored in advance in the database (20) includes one or more of the state of the industrial machine, the state of peripheral devices operating in conjunction with the industrial machine, the state of the internal structure of the industrial machine, and the state of a workpiece being machined by the industrial machine.

[0033] REFERENCE SIGNS LIST 1 Simulation system 10 Simulation device 110 Simulation unit 120 Image output unit 1201 Approximate image extraction unit 20 Database 210 Internal data 220 Industrial machine image data

Claims

1. A simulation device for an industrial machine driven and controlled by a control device, comprising: a simulation unit that reproduces the operation of the control device and generates internal data of the control device; and an image output unit that acquires and outputs an image representing the state of the industrial machine corresponding to the generated internal data from a database that stores in advance a plurality of internal data in the actual operation of the control device and an image representing the state of the industrial machine for each of the plurality of internal data.

2. The simulation device according to claim 1, wherein the image output unit includes an approximate image extraction unit that extracts, from the database, internal data similar to the generated internal data within a predetermined range and an image representing the state of the industrial machine corresponding to the similar internal data.

3. The simulation device according to claim 2, wherein the image output unit outputs an image obtained by synthesizing the generated internal data and the image extracted by the approximate image extraction unit.

4. The internal data of the control device includes any one or more of a coordinate value of a control axis, a parameter value of the control device, a value of diagnostic data of the control device, a value of modal data of the control device, a value of an interface between the control device and an external device, a value of an interface between functions within the control device, a value of a work memory within the control device, or a program code being executed by the control device. The simulation device according to any one of claims 1 to 3.

5. The image representing the state of the industrial machine stored in advance in the database includes any one or more of the state of the industrial machine, the state of peripheral devices operating in cooperation with the industrial machine, the state of the internal structure of the industrial machine, and the state of a work processed by the industrial machine. The simulation device according to any one of claims 1 to 3.

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