Robot Resumption Simulation Using Virtual Suspended-State Twins
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Solution Overview
Problem
Existing production systems face challenges in minimizing downtime when operations are suspended due to abnormalities, as unexpected changes in the environment can occur, and there is a need for efficient simulation and resumption of operations to quickly cope with system stoppages.
Innovation Solution
A control system that operates robots in a real space and simulates their suspended state in a virtual space, allowing for the resumption of operations by virtual robots based on the operation program, enabling the simulation of real space events before actual resumption and facilitating quick system response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operation suspension occurs due to abnormalities in real production systems, then system safety is protected, but production downtime increases
Solution Approach 1:
The system performs preliminary simulation of operation resumption in virtual space before actual resumption occurs. The simulation predicts potential abnormalities and prepares resumption strategies in advance, allowing the real system to resume operations quickly and safely without unexpected delays or safety incidents.
Solution Approach 2:
The invention creates a virtual copy of the production system that mirrors the real system's state and operations. By simulating resumption scenarios in this virtual copy, the system can evaluate multiple resumption strategies without affecting the real production line, thereby minimizing downtime while ensuring safety.
2Productivity
If operation resumption is performed immediately after suspension, then productivity is maintained, but safety risks increase due to unexpected environmental changes
Solution Approach 1:
Before actual operation resumption, the system performs preliminary simulation in virtual space to predict potential safety issues. This preliminary action identifies environmental changes and potential conflicts that may occur during resumption, allowing operators to prepare appropriate safety measures while maintaining productivity through quick resumption.
Solution Approach 2:
The simulation process performs preliminary anti-action by predicting and counteracting potential safety risks before they manifest in the real system. By identifying potential abnormalities in advance through virtual simulation, the system can prevent safety incidents during actual resumption while maintaining production continuity.
3Reliability
If comprehensive simulation of suspended state is performed in virtual space, then resumption safety is improved, but computational complexity increases
Solution Approach 1:
The system creates a simplified virtual copy of the production environment that captures only the essential elements needed for safety simulation. This copying approach enables comprehensive safety analysis without requiring a full-scale complex simulation of every system component, thereby improving resumption safety while managing computational complexity.
4Reliability
If virtual robot operations are simulated based on operation programs, then resumption planning is improved, but processing time for simulation increases
Solution Approach 1:
The system performs partial simulation focusing only on the critical aspects of operation resumption rather than simulating every detail of the complete operation program. This partial action approach provides sufficient planning accuracy for safe resumption while significantly reducing the processing time required for simulation.
Data Source
AI summary
A control system includes: a controller configured to operate one or more robots in a real space based on an operation program; and circuitry configured to: operate one or more virtual robots based on the operation program in a virtual space, the one or more virtual robots corresponding to the one or more robots respectively; cause the controller to suspend an operation based on the operation program by the one or more robots; simulate a suspended state of the real space after suspension of the operation by the one or more robots, in the virtual space; and resume at least a part of the operation by the one or more virtual robots based on the operation program, in the virtual space in which the suspended state of the real space has been simulated.