Conveyor Virtual Simulation Using PLC Distance Logic
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Solution Overview
Problem
Current virtual simulation methods for conveyor belts in cell module production workshops are cumbersome and prone to errors due to the need to establish multiple stop points and virtual axes, leading to inaccuracies and increased workload for engineers.
Innovation Solution
A virtual simulation method that uses a target logic block to determine the actual distance the conveyor mechanism moves during simulation, eliminating the need for stop points and virtual axes, and allowing the PLC to control the data model based on the calculated distance, thereby simplifying the simulation process and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stop points and virtual axes are established for virtual simulation, then the simulation can be performed, but the operation becomes cumbersome and errors increase
Solution Approach 1:
The patent extracts and eliminates the unnecessary stop points and virtual axes from the simulation system. By using a data model that directly represents the conveying mechanism's actual structure and movement parameters, the patent removes the intermediate abstraction layers (stop points and virtual axes) that caused operational complexity and errors, achieving both simplicity and accuracy simultaneously
Solution Approach 2:
The patent creates an accurate digital copy of the conveying mechanism through a data model that mirrors the real system's structure, parameters, and behavior. This digital twin approach allows direct interaction with the simulated mechanism without requiring additional virtual constructs like stop points or virtual axes, simplifying operations while maintaining simulation fidelity
2Manufacturing precision
If multiple stop points are calculated and added sequentially, then pallet stopping positions can be controlled, but the workload increases and simulation becomes cumbersome
Solution Approach 1:
The patent performs preliminary configuration by establishing a comprehensive data model that pre-defines all necessary movement parameters, speeds, and positions of the conveying mechanism. This preliminary setup eliminates the need for sequential calculation and addition of individual stop points during simulation, as the system can directly determine pallet positions based on the pre-configured data model
Solution Approach 2:
The data model serves multiple functions simultaneously: it defines the conveying mechanism's structure, determines pallet stop positions, calculates movement distances, and controls simulation behavior. This multi-functional approach replaces the previous specialized components (stop points, virtual axes, speed attributes) with a single universal data model, reducing both workload and setup time
Data Source
AI summary
A virtual simulation method for a conveying mechanism includes obtaining a data model of the conveying mechanism, creating a virtual conveying line according to the data model so that the data model is movable along the virtual conveying line during a simulation process, creating a target logic block used to determine an actual distance for which the data model moves each time during the simulation process, and sending the actual distance to a PLC, so that when it is determined that the actual distance is the same as a target distance for which the conveying mechanism should move each time, the PLC controls the data model to stop moving.