Virtual Production Comparison for Real-Time Operation Verification
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Solution Overview
Problem
In production systems, autonomously operating devices face challenges in verifying correct operation contents in real time due to varying conditions in the real space, making it difficult to set and verify operation parameters accurately.
Innovation Solution
A production system that includes a production device performing processing in a real space and a virtual production device performing corresponding virtual processing in a virtual space, with a comparison unit to monitor and verify the execution results, allowing real-time validation of autonomous operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If autonomous devices operate in real space with varying conditions, then operational flexibility and adaptability are improved, but verification of correct operation contents becomes difficult
Solution Approach 1:
The patent creates a virtual copy of the production device and its operating environment. The virtual production device replicates the real device's structure, parameters, and operational conditions in a virtual space, allowing verification of operation contents without being affected by real-space variations. This copying approach enables accurate verification while maintaining operational flexibility in the real device.
Solution Approach 2:
The patent introduces a virtual dimension parallel to the real physical space. By transferring the production device and its environment into this virtual dimension, the system enables verification operations that are independent of real-space conditions. The virtual space provides an additional dimension where operations can be simulated and verified without constraints from physical variations.
2Measurement precision
If operation parameters are adjusted to verify correct operation contents, then measurement precision is improved, but operation time increases
Solution Approach 1:
The patent performs verification actions in advance by simulating operations in the virtual environment before executing them in the real device. The virtual production device pre- validates operation contents, parameters, and sequences, allowing real-space operations to proceed without time-consuming verification delays. This preliminary verification in virtual space ensures precision without adding time to actual production operations.
Solution Approach 2:
By creating a virtual copy of the production system, the patent enables parallel verification operations that do not interfere with real production timing. The virtual system can perform detailed parameter adjustments and verification at high precision while the real device maintains its production schedule, eliminating the time penalty that would normally accompany precise verification.
3Reliability
If a virtual production device is introduced for verification purposes, then operational reliability is improved, but system complexity increases
Solution Approach 1:
The virtual production device serves multiple functions: it verifies operation contents, validates parameters, simulates various operating conditions, and provides a testing environment. This multi-functionality justifies the added complexity by consolidating multiple verification and testing capabilities into a single virtual system rather than requiring separate physical testing equipment for each function.
Solution Approach 2:
The patent replaces physical mechanical verification systems with a virtual information-based system. Instead of using additional physical sensors, test equipment, and manual verification procedures, the system uses virtual modeling and software-based simulation to perform verification. This substitution reduces the type of complexity from physical hardware to information processing, which can be more efficiently managed and scaled.
Data Source
AI summary
A production system includes: a production device configured to perform, to produce a product, processing on a workpiece in a real space in response to a production instruction transmitted based on a production plan; and simulation circuitry configured to: cause a virtual production device to perform, in a virtual space, virtual processing corresponding to the processing in response to the transmitted production instruction; and compare an execution result of the processing with an execution result of the virtual processing.