Automatic Machine Motion Simulation for Collision Debugging
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Solution Overview
Problem
Current simulation methods for automatic manufacturing machines are complex and inefficient, making it difficult for manufacturers to debug and visualize the motion of actuators, leading to increased design and delivery times, and a higher risk of collisions due to the lack of intuitive graphical outputs and the need for extensive 3D modeling.
Innovation Solution
A method and apparatus that integrate a first processor for creating a virtual 3D model and a second processor for controlling the motion of actuators, connected through an interface, allowing for real-time simulation and data exchange between the design and motion control environments, enabling the simulation of actuator motion and detection of potential collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If virtual visual models are developed directly in the simulation environments of motion controllers to check for collisions, then collision detection capability is improved, but the generation of graphics requires additional time adding up to the designing time, thus significantly increasing the delivery times of the machine
Solution Approach 1:
The patent creates a virtual copy of the automatic machine in a simplified graphical environment that replicates the motion laws and operational logic without requiring full 3D modeling. This virtual model allows collision detection and motion validation while significantly reducing the time required compared to developing detailed virtual visual models in motion controller simulation environments.
2Manufacturing precision
If three-dimensional modelling programs are used to link several components of an automatic machine so that they move together, then the correct moving of linked parts can be tested, but it is not possible to test actual movements that are present in the program of the motion controller without too much effort
Solution Approach 1:
The patent replaces complex mechanical 3D modeling and manual movement coordination with a software-based system that automatically imports motion laws from the motion controller program. The system uses computational methods to simulate actual actuator movements and their effects on machine components, eliminating the need for manual configuration and reducing setup effort while maintaining accuracy.
3Loss of information
If motion controllers provide simulation output as graphs to debug actuator motion, then the logic of actuator operation can be visualized, but the graphs are not always easily readable and make it difficult to understand in detail what the motions of the last followers are going to be
Solution Approach 1:
The patent transforms the one-dimensional graphical output of motion controllers into a two-dimensional simplified graphical representation that displays the positions and movements of machine components in a more intuitive format. This visual representation shows the actual positions of followers and potential collision points, making the simulation output easily readable and providing detailed information about component motions without the complexity of traditional oscilloscope graphs.
Data Source
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AI summary
A method for simulating the motion of at least part (5) of an automatic machine (1) for manufacturing or packaging consumer articles (3) comprising the steps of defining a three-dimensional model (13), in a computer-aided design environment (14), of the part (5) whose motion is to be simulated; programming a software (SW) for controlling the motion of one or more movable operating elements (2) of the part (5) of the automatic machine (1); extracting a data set (DS) about the commanded position (P) established, at a given time instant (t1, t2, ..., tn), for said one or more movable operating elements (2); communicating the data set (DS) about the commanded position (P) in the aided design environment (14); and simulating the movement of said one or more movable operating elements (2) by changing the position of said one or more movable operating elements (2) according to the data set (DS) about the commanded position (P).