Controller Workpiece Simulation for Conveyance Systems
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Solution Overview
Problem
Conveyance systems face challenges in performing accurate simulations due to heavy calculation loads and the need for additional simulation devices, which can introduce time lags and require extensive communication, making it difficult to test real-time communication and calculation processing in conveyance systems.
Innovation Solution
A controller for conveyance systems that includes an external interface, settings input part, control-program execution part, constraint-condition change part, workpiece simulation part, sensor simulation part, and input/output switching part, allowing for the generation of sensor simulation information based on estimated workpiece positions and constraint conditions, enabling simulations to be performed without relying heavily on the type of conveyance system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulation is performed using external simulation devices, then simulation capability is improved, but communication complexity and time lag increase
Solution Approach 1:
The patent merges the simulation functionality into the controller itself by integrating a workpiece simulation unit and sensor simulation unit within the controller's processing circuit. This eliminates the need for separate external simulation devices and reduces communication complexity between the controller and simulation devices, while maintaining reliable simulation capability for testing control programs.
Solution Approach 2:
The controller is designed to perform multiple functions: it not only controls the actuators but also simulates workpiece movement and sensor signals internally. This multi-functionality allows the same device to serve both control and simulation purposes, reducing the need for additional dedicated simulation equipment and simplifying the overall system architecture.
2Reliability
If simulation is performed using external simulation devices, then simulation capability is improved, but time lag increases
Solution Approach 1:
By integrating the simulation units within the controller, the patent eliminates communication delays between external devices. The workpiece simulation unit and sensor simulation unit operate internally within the controller's processing circuit, enabling real-time simulation without the time lags associated with external device communication.
Solution Approach 2:
The controller performs simulation calculations internally and simultaneously with control operations, rather than requiring separate pre-simulation steps. This allows the simulation of sensor signals based on estimated workpiece positions to be generated in real-time during actual operation, eliminating time lags.
3Measurement precision
If detailed simulation is performed, then measurement precision is improved, but calculation load increases
Solution Approach 1:
The patent implements a balanced simulation approach where the workpiece simulation unit estimates workpiece positions based on actuator drive information and constraint conditions, and the sensor simulation unit generates corresponding sensor signals. This partial simulation provides sufficient accuracy for testing control programs without requiring full-precision physical simulation, thereby reducing calculation load while maintaining adequate measurement precision.
Solution Approach 2:
The simulation system dynamically adjusts calculation precision based on operational requirements. The workpiece simulation unit calculates positions using drive information and constraint conditions, generating sensor signals with appropriate precision for each simulation scenario, thereby optimizing the balance between measurement precision and calculation load.
Data Source
AI summary
A workpiece simulation part estimates the amount of movement of the workpiece from drive information and estimates the current position of the workpiece by adding the amount of movement to the previous position of the workpiece, the drive information being generated for, among at least one actuator, an actuator that is assumed to constrain the workpiece under the constraint conditions. A sensor simulation part uses the current position of the workpiece to generate sensor simulation information. An input/output switching part transmits the drive information to the workpiece simulation part and transmits the sensor simulation information as alternate information of the sensor information to the control-program execution part.