Controller Simulation with Shared Memory for Data Exchange
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Solution Overview
Problem
Conventional simulation environments for factory automation systems lack the ability for programmable controllers and motion controllers to exchange data, limiting the simulation of external input/output operations and increasing labor time for system startup and debugging.
Innovation Solution
A simulation device with a data sharing unit that allows cooperation between simulators for programmable and motion controllers, enabling data exchange and synchronization of operations through a linkage function processing unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simulators for programmable controller and motion controller operate independently in conventional simulation environment, then each simulator can execute its user program separately, but data cannot be exchanged between controllers and external input/output data cannot be incorporated into the simulation
Solution Approach 1:
The patent merges multiple independent simulators (programmable controller simulator and motion controller simulator) into a unified simulation device that shares common memory space. This allows the simulators to execute separately while simultaneously enabling data exchange through the shared memory, resolving the contradiction between independent operation and data exchange capability
Solution Approach 2:
The shared memory acts as an intermediary between the programmable controller simulator and motion controller simulator. It provides a common data space that enables indirect communication and data exchange between the two simulators without requiring direct connection, thus maintaining ease of setup while enabling data exchange
2Productivity
If simulators operate independently without data sharing, then system complexity is reduced, but debugging efficiency and startup time increase due to inability to perform integrated simulation
Solution Approach 1:
The shared memory serves multiple functions simultaneously: it acts as data storage for both simulators, provides communication channel between them, enables integrated simulation of multiple controllers, and supports external I/O data incorporation. This multi-functionality improves debugging efficiency without proportionally increasing system complexity
3Loss of time
If conventional independent simulation is used, then less computational resources are required, but labor time for system startup and on-site adjustment increases
Solution Approach 1:
The patent enables preliminary integrated simulation of multiple controllers and their data interactions before actual system deployment. By performing comprehensive debugging and validation in the simulated environment with shared data space, potential issues are identified and resolved beforehand, significantly reducing on-site startup time and adjustment requirements
Data Source
AI summary
A simulation device includes a first simulation circuitry to simulate the operation performed by a programmable controller in accordance with a first program, and second simulation circuitry to simulate the operation performed by a motion controller in accordance with a second program. Further, there is a data sharing memory into and from which the first simulation circuitry and the second simulation circuitry are allowed to write and read data.