Integrated Simulation for PLC Robot Control
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Solution Overview
Problem
Conventional PLC/PAC controllers face limitations in motion planning and control of robotic manipulators with multiple degrees of autonomy, particularly in large workcells, due to deficiencies in programming languages and non-homogeneous environments, which hinder integrated simulation and validation capabilities.
Innovation Solution
An integrated simulation system that allows for the simultaneous instantiation of either actual or simulated workcells and robot manipulators, using a programmable logic controller with modules for workcell and robot manipulator control, enabling user-configurable real-time feedback and visualization of both systems, facilitating safe and efficient software development.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional PLC/PAC controllers are used to control robotic manipulators in large workcells, then the system can handle large numbers of I/O signals and complex workcell operations, but the controller demonstrates only limited success in motion planning and control due to deficiencies in programming languages
Solution Approach 1:
The system divides control into two independent modules: a PLC/PAC for workcell control and a robot controller for manipulator control. Each module operates with its own optimized programming environment, allowing the PLC to handle I/O signals while the robot controller specializes in motion planning and control.
Solution Approach 2:
A communication interface acts as an intermediary between the PLC/PAC and robot controller, enabling coordinated operation. The PLC sends high-level commands through this interface, which the robot controller translates into precise motion control actions, resolving the limitation of PLC programming languages for motion control.
2Ease of manufacture
If separate controller modules are used for workcell and robot manipulator control, then each controller can be optimized for its specific function, but the programming and maintenance environments become non-homogeneous
Solution Approach 1:
The system provides a universal programming interface that allows both PLC and robot controller to be programmed using consistent methodologies. The communication protocol and data structures are standardized, enabling homogeneous programming practices across different controller types while maintaining their specialized functions.
3Reliability
If integrated simulation is implemented allowing simultaneous instantiation of actual and simulated workcells and robot manipulators, then safe and efficient software development is enabled, but the system complexity and configuration requirements increase
Solution Approach 1:
The system creates virtual copies (simulated workcell and robot manipulator) that mirror the physical systems. These simulations can be instantiated independently or concurrently with actual hardware, allowing safe software validation without risking damage to physical equipment. The simulation environment replicates all I/O signals and motion characteristics for realistic testing.
Data Source
AI summary
In an automated system which includes a robot manipulator, a workcell, and a control system implemented on a hardware platform based on a programmable logic controller (“PLC”), a method and apparatus for performing integrated simulation that does not require the presence of both the robot manipulator and the workcell. If one component is real, the other component is simulated so as to be sufficiently responsive to responses from the real component such that the real component is unable to discern that the other component is not also real. A computing device simultaneously displays simulacra of both the components, real and simulated, and visualizations of the responses provided by each.