Integrated PLC-Robot Control With Vision to Cut Transmission Delay
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Solution Overview
Problem
Existing control systems in factory automation face challenges with high transmission delays due to independent motion controllers and visual sensors, hindering high-speed control and complicating program development.
Innovation Solution
A control device integrating a PLC engine, robot control engine, image processing engine, and simulation module that allows for cyclic execution of programs, simulation of control targets, and visualization of control states, enabling simpler configuration and facilitating program development by allowing arbitrary combination and simulation of control processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plurality of devices (motion controller and visual sensor) exchange data via an interface, then data communication between devices is enabled, but transmission delay increases and high-speed control is hindered
Solution Approach 1:
The patent combines multiple control functions (PLC control, robot control, image processing) into a single integrated control device. This eliminates the need for data exchange between separate devices via interfaces, thereby reducing transmission delay while maintaining full communication capability among all control functions.
2Adaptability or versatility
If independent motion controller and visual sensor are used, then device functionality is maintained, but system configuration becomes complex and program development is difficult
Solution Approach 1:
The patent integrates PLC control, robot control, and image processing into a unified control device with a common controller. This reduces system configuration complexity while preserving all individual device functionalities through modular software components that can be independently configured and programmed.
Solution Approach 2:
The control device is designed as a universal platform that can perform multiple control functions simultaneously. The single controller can execute PLC programs, robot control programs, and image processing tasks, eliminating the need for multiple specialized devices and simplifying system configuration.
3Ease of manufacture
If simulation module is constructed according to user setting, then program development is facilitated and verification is enabled, but system complexity increases
Solution Approach 1:
The patent implements a simulation module that creates virtual copies of the control target, robot, and camera based on user settings. This allows program development and verification to proceed without physical hardware, facilitating easier programming while the simulation functionality is integrated into the existing control device architecture rather than adding separate systems.
Data Source
AI summary
Provided is a configuration capable of realizing complicated control with a simpler configuration and facilitating program development. A control device for controlling a control target includes: a PLC engine configured to cyclically execute a program including a sequence instruction; a robot control engine configured to control a robot; an image processing engine configured to execute image processing on an image from a camera; and a simulation module configured to simulate at least a part of the control target, the robot, and the camera, the simulation module being constructed according to user setting.