Programmable Controller Simulation Cycle Synchronization
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Solution Overview
Problem
Current 3D CAD simulators for manufacturing equipment debugging require significant designer effort to synchronize the cycle of the programmable controller with the simulation, leading to increased development time and potential simulation accuracy issues due to data reflection errors.
Innovation Solution
A simulation system where a programmable controller temporarily stops its computing process and stores results, while a simulation device temporarily stops its simulation and transmits a stop release command to synchronize cycles, allowing for high-accuracy simulations without burdening the designer with manual synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the cycle of the 3D CAD simulator is synchronized with the cycle of the actual programmable controller by correcting the user program, then simulation accuracy is improved, but the burden on the designer increases
Solution Approach 1:
The system enables self-service synchronization where the programmable controller and simulation device automatically coordinate their cycles through built-in temporary stop states and stop release commands, eliminating the need for designer intervention in program correction
Solution Approach 2:
A stop release instructing command acts as an intermediary signal between the simulation device and programmable controller, mediating the cycle synchronization process and enabling automatic coordination without direct designer involvement
2Productivity
If the programmable controller continuously executes computing cycles, then productivity is maintained, but simulation accuracy decreases due to data reflection errors
Solution Approach 1:
The programmable controller employs periodic temporary stop states at the end of each computing cycle, pausing execution to allow data transmission to the simulation device, then resuming with stop release commands to maintain overall productivity while ensuring synchronization accuracy
Data Source
AI summary
A programmable controller includes a command executing engine unit that performs a user program and performs a computing process and nonvolatile memory that stores the result of the computing process. The command executing engine unit transitions to a temporary stop state in which a new cycle of computing process is not performed and stores the result of a cycle of computing process in the nonvolatile memory when the cycle of computing process of the user program ends, and releases the temporary stop state and transmits the result of the cycle of computing process stored in the nonvolatile memory to a simulation device when a stop release instructing command instructing to release the temporary stop state is received from the simulation device.