Virtual Machine Motion Profiling for Accurate Controller Simulation
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Solution Overview
Problem
Current industrial automation simulation systems lack the ability to accurately emulate the motion and operation of physical machines, leading to discrepancies between simulated and actual machine performance, which affects the design and prototyping phases in industrial manufacturing.
Innovation Solution
A computing system that analyzes the motion of a solid model to generate a motion profile, configures an industrial controller system based on this profile, and compares the motion of the simulation controlled by the industrial controller system to the original motion profile, allowing for fine-tuning and improved emulation of machine operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional simulation systems are used to emulate machine operations, then design and prototyping can be performed, but the simulation accuracy does not match actual machine performance
Solution Approach 1:
The system captures actual motion data from physical machines using sensors and feeds this data back to continuously adjust and refine the simulation model parameters. This closed-loop feedback mechanism ensures the simulation accurately reflects real machine behavior, resolving the contradiction between simulation accuracy and emulation fidelity.
Solution Approach 2:
The system dynamically adjusts simulation parameters based on captured motion profiles from actual machines. By changing parameters such as mass, inertia, friction coefficients, and stiffness values to match real-world measurements, the simulation achieves both high measurement precision and reliability in emulating actual machine performance.
2Measurement precision
If detailed motion analysis and controller configuration are performed to improve simulation accuracy, then emulation fidelity increases, but design cycle time increases
Solution Approach 1:
The system performs motion analysis and captures motion profiles during the initial setup phase before detailed design work begins. By preparing simulation parameters and motion data in advance, the system enables rapid iterations during the design cycle without sacrificing accuracy, thus reducing overall design cycle time while maintaining high motion analysis accuracy.
Solution Approach 2:
The system creates accurate copies of actual machine motion profiles through sensor data capture and uses these copies to drive the simulation. This copying approach allows the simulation to replicate real machine behavior without requiring repeated physical testing and measurement, significantly reducing design cycle time while preserving motion analysis accuracy.
3Reliability
If comprehensive sensor data capture and motion profile analysis are implemented, then simulation realism improves, but system complexity increases
Solution Approach 1:
The system extracts only the essential motion parameters and characteristics needed for accurate simulation from the comprehensive sensor data. By selecting and extracting key parameters such as position, velocity, acceleration, and critical motion profiles, the system maintains simulation realism while avoiding the complexity of processing and managing all possible sensor data.
Solution Approach 2:
The system uses a unified motion capture and analysis framework that can handle multiple sensor types and machine configurations through a single integrated platform. This universal approach allows the system to achieve comprehensive simulation realism without the complexity of multiple separate systems, as the same core technology adapts to different sensing and modeling needs.
Data Source
AI summary
Systems, methods, and software to facilitate simulating machines used in industrial automation are disclosed herein. In at least one implementation, motion of a solid model of a machine is analyzed to generate a motion profile of the solid model. An industrial controller system is then configured based on the motion profile of the solid model. A simulation of the machine controlled by the industrial controller system is executed, and motion of the simulation of the machine as controlled by the industrial controller system is analyzed. The motion of the simulation of the machine is then compared to the motion profile of the solid model to determine how closely the motion of the simulation of the machine as controlled by the industrial controller system matches the motion profile of the solid model.