Virtual FA Control Emulation for PLC-Robot Timing Debugging

Solution Overview

Problem

Current factory automation systems lack the ability to synchronously and asynchronously execute different types of control programs, limiting precise simulation and debugging capabilities for transportation devices like arm robots and moving tables.

Innovation Solution

The implementation of a virtual FA system with emulators that simulate the behavior of real FA system components, allowing for synchronous and asynchronous execution modes through a timer-generated virtual time, enabling precise simulation and debugging of control programs for PLCs and robot controllers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If control programs for different transportation devices are executed synchronously, then simulation accuracy and debugging precision are improved, but execution time increases and productivity decreases

Engineering Contradiction:

Improvesimulation accuracyVSAvoidexecution speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The system dynamically switches between synchronous and asynchronous execution modes based on the simulation requirements. The execution mode is not fixed but can be changed according to the specific debugging or simulation phase, allowing the system to adapt its timing behavior to optimize both accuracy and efficiency.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the execution parameter (synchronization state) of control programs. By adjusting whether programs execute in synchronous or asynchronous mode, the system can transform the timing characteristics to match different operational requirements, thereby resolving the contradiction between precision and speed.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If control programs for different transportation devices are executed asynchronously, then execution speed and productivity are improved, but simulation accuracy and debugging precision deteriorate

Engineering Contradiction:

Improveexecution speedVSAvoiddebugging accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system dynamically switches between synchronous and asynchronous execution modes based on the simulation requirements. The execution mode is not fixed but can be changed according to the specific debugging or simulation phase, allowing the system to adapt its timing behavior to optimize both accuracy and efficiency.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the execution parameter (synchronization state) of control programs. By adjusting whether programs execute in synchronous or asynchronous mode, the system can transform the timing characteristics to match different operational requirements, thereby resolving the contradiction between precision and speed.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If a single execution mode is used for all control programs, then device complexity is reduced, but adaptability to different simulation scenarios deteriorates

Engineering Contradiction:

Improveexecution mode managementVSAvoidsimulation scenario flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The simulation device is designed with multi-functionality, supporting both synchronous and asynchronous execution modes within a single system. This universal design allows the same device to handle diverse simulation scenarios without requiring separate specialized systems, thereby achieving high adaptability without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3441831B1Information processing device, information processing method, and information processing program

Publication Date: 2021.09.15 OMRON CORP

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AI summary

An information processing device (100) includes an actuator emulator (155) that simulates a behavior of a drive apparatus that is for driving a first control target, an actuator emulator (165) that simulates a behavior of a drive apparatus that is for driving a second control target that cooperates with the first control target, a timer (140) that generates a virtual time, and an execution part (151A) that executes a PLC program (111) for controlling the actuator emulator (155) and a robot program (112) for controlling the actuator emulator (165). Execution modes of the control programs used by the execution part (151A) include a synchronous execution mode in which the PLC program (111) and the robot program (112) are synchronously executed in accordance with a virtual time and an asynchronous execution mode in which the PLC program (111) and the robot program (112) are asynchronously executed.