Virtual FA Emulation for Synchronized PLC and Robot Control
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Solution Overview
Problem
Existing factory automation systems cannot synchronously execute different types of control programs, limiting the ability to simulate the synchronous operation of various transportation devices, such as arm robots and moving tables, which are crucial for precise automation processes.
Innovation Solution
A virtual FA system is implemented, utilizing emulators and a common timer to synchronize the execution of control programs written in different programming languages, allowing for precise simulation of operations across different types of control targets like arm robots and moving tables through a synchronized execution mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different types of control programs are executed independently, then each control program can be executed according to its own programming language and execution logic, but synchronous operation of various transportation devices cannot be simulated
Solution Approach 1:
The patent introduces a simulation control unit as an intermediary component that receives control programs from multiple controllers, translates them into a unified execution format, and coordinates their synchronous execution. This mediator enables different control programs written in various programming languages to operate synchronously by acting as a bridge between heterogeneous control systems.
Solution Approach 2:
The simulation control unit is designed with multi-functionality to handle diverse control programs from different controller types. It can interpret and execute control programs written in different programming languages (such as ladder diagrams, structured text, and robot-specific languages) through a unified execution engine, making the simulation system universally applicable to various transportation devices.
2Manufacturing precision
If a simulation device is used to test control programs, then program validation can be performed, but synchronous execution of different control program types is not achieved
Solution Approach 1:
The system performs preliminary translation of control programs from various programming languages into a unified intermediate representation before execution. This preliminary action allows the simulation control unit to pre-process and standardize control programs, enabling efficient synchronous execution during actual simulation while maintaining high validation accuracy.
Solution Approach 2:
The simulation control unit dynamically adjusts its execution strategy based on the types and characteristics of control programs being executed. It can switch between different execution modes (such as step-by-step debugging mode and continuous simulation mode) and dynamically allocate computational resources to maintain both accuracy and efficiency during program validation.
Data Source
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AI summary
An information processing device (100) includes an actuator emulator (155) simulating a behavior of a first drive apparatus that is for driving a first control target, an actuator emulator (165) simulating a behavior of a second drive apparatus that is for driving a second control target, a storage device for storing a PLC program (111) including an instruction group with respect to the actuator emulator (155) and a robot program (112) including an instruction group with respect to the actuator emulator (165), a timer (140) generating a virtual time, and a PLC emulator (151) for repeatedly executing the instruction group included in the PLC program (111) in each predetermined first control period in accordance with measurement using the virtual time, and a robot controller emulator (161) for sequentially executing the instruction group included in the robot program (112) in a predetermined execution order in accordance with the virtual time.