Robot Test Installation Using Virtual Modeling for Control Program Validation
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Solution Overview
Problem
Conventional testing methods for control programs in robot systems, such as painting installations, are inadequate as they fail to simulate real-world conditions and interactions, leading to delayed commissioning, potential damage, and incomplete testing of safety-oriented parts.
Innovation Solution
A test installation that simulates the function and structure of a robot system using modeling equipment to replace peripheral components, allowing for dynamic testing without real components, and includes a data bus structure similar to the actual system for comprehensive control program validation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If control programs are tested in the actual painting installation, then real-world interactions and safety-oriented parts can be tested, but the risk of damage to equipment increases and commissioning time is extended
Solution Approach 1:
The patent creates a virtual copy of the painting installation through a simulation environment that replicates the physical system's behavior, sensors, actuators, and control logic. This virtual model allows comprehensive testing of control programs including safety-oriented parts without risking damage to actual equipment. The simulation environment mirrors the real system's architecture and operational characteristics, enabling realistic test scenarios to be executed on the virtual copy rather than the physical installation.
2Object-affected harmful factors
If control programs are tested individually in sub-systems, then testing can be performed without risking the whole installation, but interaction between control programs and other sub-systems cannot be tested
Solution Approach 1:
The patent merges individual sub-system simulations into a unified virtual painting installation that preserves all interconnections and interactions between components. The simulation environment integrates robot controls, peripheral components, sensors, and actuators in their actual operational relationships, allowing comprehensive system-level testing while maintaining the safety benefits of virtual execution. This combined approach enables testing of control program interactions that individual sub-system testing cannot provide.
3Reliability
If control programs are tested in the painting installation during pre-commissioning, then realistic operating conditions can be tested, but only non-risky conditions can be tested and commissioning time is extended
Solution Approach 1:
The patent performs comprehensive control program testing in the virtual simulation environment before actual commissioning of the physical painting installation. The simulation allows extreme and boundary conditions to be tested preliminarily without risk, identifying and resolving issues before they affect the real system. This preliminary testing in virtual space accelerates the overall commissioning process by eliminating the need for extensive iterative testing on the actual installation, thereby reducing commissioning time while maintaining testing realism.
4Reliability
If the painting installation is tested at customer premises, then real operating conditions are present, but testing delays commissioning and software errors require significant effort to remove
Solution Approach 1:
The patent executes comprehensive control program validation and error detection in the virtual simulation environment before deployment to customer premises. The simulation reproduces real operating conditions and customer-specific configurations, allowing all software errors and operational issues to be identified and corrected preliminarily. This preliminary action ensures that when the system is installed at the customer site, it is already optimized and ready for immediate commissioning, eliminating delays associated with on-site debugging and testing.
Data Source
AI summary
The invention relates to a test installation for testing control programs for a real robot installation, particularly for a lacquering installation, having a plurality of robot controllers (2.1-2.n), which each contain a control program and correspond to robot controllers (2.1-2.n) in the real robot installation, at least one control unit (4) for co-ordinating the robot controllers (2.1-2.n), wherein the control unit (4) contains a control program and corresponds to a control unit (4) in the real robot installation, and also having a first data bus (3) which connects the robot controllers (2.1-2.n) to one another and/or to the control unit (4), wherein the first data bus (3) corresponds to a data bus in the real robot installation. It is proposed that the test installation additionally have a modelling device (9) which is connected to the first data bus (3) and simulates peripheral components of the real robot installation, so that the control programs can be tested without the peripheral components. The invention also comprises an appropriate test method.