Simulator for Factory Automation with Visual Sensor Tracking

Solution Overview

Problem

Existing simulation techniques for factory automation systems, particularly those involving visual sensors, lack precision in modeling and simulating the behavior of systems with moving components like conveyor tracking systems, leading to inefficiencies in system evaluation and improvement processes.

Innovation Solution

A simulator is developed that creates a three-dimensional virtual space with a visual sensor and processing device, allowing for precise image measurement and control operation simulation, incorporating preliminary image data to accurately model and reproduce the behavior of systems, including correction for timing delays and positional discrepancies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If existing simulation techniques are used for factory automation systems with visual sensors, then system evaluation can be performed, but measurement precision and timing accuracy are insufficient

Engineering Contradiction:

Improveimage measurement precisionVSAvoidsimulation accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-obtaining image data before simulation and storing it with associated position information. This allows the simulation to use accurate, pre-processed image measurements rather than generating them during simulation, thereby improving measurement precision while maintaining simulation reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses copying by creating a virtual copy of the actual system in three-dimensional virtual space, including virtual visual sensors that replicate the behavior of physical sensors. This virtual copy enables precise image measurement simulation without requiring physical hardware, improving both measurement precision and simulation reliability.

Inventive Principle:

Principle #26Copying

2Reliability

If physical system installations are used for evaluation and improvement, then accurate system behavior can be observed, but costs and time constraints increase

Engineering Contradiction:

Improvesystem evaluation accuracyVSAvoidevaluation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent creates a virtual copy of the physical factory automation system in three-dimensional virtual space, including carriers, visual sensors, and processing devices. This virtual model enables accurate system evaluation without physical installations, significantly reducing both cost and time while maintaining evaluation reliability.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical physical system with a computational virtual system. Instead of physically installing and operating hardware for evaluation, the system uses software-based simulation that replicates physical behavior, thereby eliminating time constraints associated with physical setup while maintaining evaluation accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If physical system installations are used for evaluation and improvement, then accurate system behavior can be observed, but costs and time constraints increase

Engineering Contradiction:

Improvesystem evaluation accuracyVSAvoidsimulation system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a virtual copy of the physical factory automation system in three-dimensional virtual space, including carriers, visual sensors, and processing devices. This virtual model enables accurate system evaluation without physical installations, significantly reducing both cost and time while maintaining evaluation reliability.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical physical system with a computational virtual system. Instead of physically installing and operating hardware for evaluation, the system uses software-based simulation that replicates physical behavior, thereby eliminating time constraints associated with physical setup while maintaining evaluation accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10262406B2Simulator, simulation method, and simulation program

Publication Date: 2019.04.16 OMRON CORP

AI summary

A simulator includes a measurement unit that performs image measurement of preliminarily obtained image data corresponding to processing performed using a visual sensor, an execution unit that executes a control operation for generating a control instruction directed to a processing device based on a measurement result obtained by the measurement unit and for generating a read instruction directed to the measurement unit for reading the image data, a storage unit that stores the image data read in response to the read instruction in a manner associated with information indicating a position or a displacement of a carrier serving as a reference for the image measurement performed in response to the read instruction, and a reproduction unit that reproduces a behavior of the created system based on time-series data for the control operation output from the execution unit and the information associated with the image data stored in the storage unit.