Virtual Conveyor Simulation Using PLC Distance Logic
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Solution Overview
Problem
Current virtual simulation methods for conveyor belts in cell module production workshops are prone to errors and are cumbersome due to the need to establish Stop Points and virtual axes, leading to inaccuracies and increased workload.
Innovation Solution
A virtual simulation method that determines the actual distance of the conveying mechanism using a target logic block, eliminating the need for Stop Points and virtual axes, and uses a formula to calculate this distance based on cumulative movement and target distance, improving accuracy and simplifying the simulation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Stop Points are established for each pallet stop position according to process files and speed attributes, then the pallet can be stopped at the correct position, but large errors are likely to occur and the operation is cumbersome
Solution Approach 1:
The patent extracts and eliminates the Stop Point establishment step from the simulation process. Instead of manually calculating and adding Stop Points based on process files and speed attributes, the system directly uses the target distance parameter to control pallet stopping, removing the source of errors and operational complexity
Solution Approach 2:
The patent changes the control parameter from multiple parameters (process files, speed attributes, calculated stop positions) to a single target distance parameter. This simplifies the operation by allowing direct input of the distance the conveying mechanism should move, eliminating the need for complex calculations and reducing errors
2Reliability
If a virtual axis is established to obtain real-time position through interaction with PLC, then the conveying mechanism can be controlled, but the operation becomes more cumbersome and errors increase
Solution Approach 1:
The patent removes the virtual axis establishment step from the system. Instead of creating a virtual axis to interact with the PLC for real-time position feedback, the system directly uses the target distance parameter to control the conveying mechanism, eliminating an entire layer of complexity while maintaining reliability
Solution Approach 2:
The patent merges the position control function directly into the target distance parameter. The target distance inherently contains the position information needed for control, eliminating the need for separate virtual axis configuration and PLC interaction layers
3Measurement precision
If Stop Points are calculated in sequence according to process files and speed attributes, then the pallet stop position can be determined, but the workload increases and errors are likely
Solution Approach 1:
The patent extracts and eliminates the sequential calculation process of Stop Points from the simulation setup. By using the target distance parameter directly, the system removes the time-consuming steps of reading process files, calculating based on speed attributes, and adding Stop Points one by one
Solution Approach 2:
The patent performs the position determination action in advance by directly setting the target distance parameter. This eliminates the need for sequential calculations during simulation setup, as the target distance already encapsulates the required stop position information
Data Source
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AI summary
Embodiments of the present application relate to the field of virtual simulation, and disclose a virtual simulation method and apparatus for a conveying mechanism, an electronic device, a PLC, and a medium. The virtual simulation method includes: obtaining a data model of the conveying mechanism; creating a virtual conveying line according to the data model, so that the data model is movable along the virtual conveying line during a simulation process; creating a target logic block, wherein the target logic block is used to determine an actual distance for which the data model moves each time during the simulation process; and sending the actual distance to a PLC, so that when it is determined that the actual distance is the same as a target distance for which the conveying mechanism should move each time, the PLC controls the data model to stop moving. In this way, simulation errors can be reduced and a simulation operation can be simplified while virtual simulation is performed on a conveying mechanism.