CN112581850A - Virtual debugging system of multifunctional production line and equipment - Google Patents
Virtual debugging system of multifunctional production line and equipment Download PDFInfo
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- CN112581850A CN112581850A CN201910927849.6A CN201910927849A CN112581850A CN 112581850 A CN112581850 A CN 112581850A CN 201910927849 A CN201910927849 A CN 201910927849A CN 112581850 A CN112581850 A CN 112581850A
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09B—EDUCATIONAL OR DEMONSTRATION APPLIANCES; APPLIANCES FOR TEACHING, OR COMMUNICATING WITH, THE BLIND, DEAF OR MUTE; MODELS; PLANETARIA; GLOBES; MAPS; DIAGRAMS
- G09B25/00—Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes
- G09B25/02—Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes of industrial processes; of machinery
Abstract
The invention discloses a multifunctional production line and a virtual debugging system of equipment, which comprises a hardware part and a software part, wherein the hardware part comprises a rack, the front side of the lower part of the rack is also provided with a control cabinet, the control cabinet in the hardware part comprises a universal part and a replaceable part, the hardware part is provided with a VR interface, the software part of the software part comprises equipment simulation software, PLC (programmable logic controller) and HMI (human machine interface) simulation software, a plurality of sets of digital prototype models and communication interface programs, and controllers in the software part and the hardware part adopt communication protocols such as OPC (optical proximity correction) and TCP/IP (transmission control protocol/Internet protocol) to exchange data. The virtual prototype is adopted, so that the flexibility is realized, the occupied site is reduced, and the hardware investment cost is saved; the real production scene can be restored in simulation software by taking the real factory equipment as a prototype, and the system can also carry out physical connection on a plurality of single-machine equipment through network cables and an exchanger; the problem of insufficient actual operation time of a single device or a production line can be solved.
Description
Technical Field
The invention relates to a debugging and maintaining system, in particular to a virtual debugging system for a multifunctional production line and equipment.
Background
At present, electromechanical debugging equipment aiming at teaching in the market mostly adopts a traditional mode of combining PLC hardware with mechanical hardware, and the following problems of professional colleges and universities using traditional training equipment are solved: 1. the teaching equipment aims at training, is excessively formalized, has a scene separated from the reality and cannot return to real production; 2. the teaching production line purchased by the school can only be used for demonstration, and the actual teaching cannot be developed, and the actual teaching is finally completed through single-machine equipment or a single workstation; 3. the school equipment has high purchase cost and site occupation and maintenance cost; 4. the real equipment has a high damage risk, and students often dare not to operate by hands; 5. the equipment is limited, and diversified troubleshooting training is difficult to develop; 6. some schools have old equipment, the training content is solidified, the new technology teaching cannot be adapted, course planning with talents suitable for high-level positions of the manufacturing industry as a core is difficult to implement, 5. industry 4.0, intelligent manufacturing is the current trend, students must learn related technologies to adapt to external requirements, some schools have related technology gaps, and 6. the existing system has single function and cannot realize complex functions.
Disclosure of Invention
The present invention is directed to a virtual debugging system for a multifunctional production line and a device, so as to solve the problems in the background art.
In order to achieve the purpose, the invention provides the following technical scheme:
a virtual debugging system of a multifunctional production line and equipment comprises a hardware part and a software part, wherein the hardware part comprises a rack, the front side of the lower part of the rack is also provided with a control cabinet, and a human-machine operation interface (HMI) is embedded and installed on a replaceable panel;
the control cabinet in the hardware part comprises a universal part and a replaceable part, and the hardware part is provided with a VR interface.
The software part comprises equipment simulation software, PLC and HMI simulation software, a plurality of sets of digital prototype models and communication interface programs, the controllers in the software part and the hardware part exchange data by adopting communication protocols such as OPC, TCP/IP and the like, and the software part also comprises related communication interface programs for secondary development.
As a further scheme of the invention: adjustable callus on the sole is installed to the bottom four corners position of frame, the left and right sides face of frame is equipped with the curb plate, and the backplate is still installed at the back of frame, the display is installed in the first half embedding of frame, and the top of frame is equipped with the three-colour signal lamp pole, and the inside of frame still is equipped with host computer.
As a still further scheme of the invention: the bottom of switch board is equipped with the gyro wheel, and the articulated switch board door that installs in front side of switch board.
As a still further scheme of the invention: still be equipped with servo motor, step motor, ordinary motor, variable frequency speed control motor, voltage current sensing, temperature and humidity sensing, photoelectric switch, proximity switch, PLC and IO module, knob switch, reset button, scram button, relay and binding post on the removable panel, PLC, HMI, signal converter module and computer on the removable panel pass through switch and net twine connection.
As a still further scheme of the invention: the PLC, the HMI, the signal converter module and the computer host on the replaceable panel are connected with the network cable through the switch, and data interaction is carried out among the PLC, the HMI, the signal converter module and the computer host.
As a still further scheme of the invention: the servo motor is divided into two different control modes of pulse and communication, and the stepping motor is divided into two different control modes of pulse and analog quantity.
Compared with the prior art, the invention has the beneficial effects that:
1. the system can download professional troubleshooting programs and troubleshooting digital prototype models in a PLC (programmable logic controller), then start debugging the digital prototype models, on the premise of faults such as sensor faults, program parameter setting errors, mechanical positioning faults, mechanical interference and the like, the models cannot normally run, fault points of equipment are found through preferred positioning faults, then the fault points are repaired (corresponding operation is carried out on a replaceable panel according to a manual or corresponding setting is carried out in program and simulation software), finally the digital prototype models are debugged again until the faults are eliminated, a virtual prototype is adopted, flexibility is achieved, the occupied area is reduced, and the hardware investment cost is saved; the real production scene can be restored in simulation software by taking the real equipment of the factory as a prototype.
2. The system can also physically connect a plurality of single-machine equipment with the switch through network cables; the problem of insufficient actual operation time of a single device or a production line can be solved.
3. The system does not depend on a mechanical body, can load and edit various scene models, can perform virtual debugging of various devices, and is simple and convenient.
Drawings
Fig. 1 is a schematic structural diagram of a virtual debugging system for a multifunctional production line and equipment.
Fig. 2 is a schematic structural diagram of a hardware part in a virtual debugging system of a multifunctional production line and equipment.
Fig. 3 is a schematic diagram of connection of multiple devices in a multifunctional production line and a virtual device debugging system.
FIG. 4 is a flow chart of a virtual debugging system for a multifunctional production line and equipment.
In the figure: 1-hardware part, 2-software part, 10-frame, 11-side plate, 12-display, 13-three-color signal lamp post, 14-control cabinet, 15-roller, 16-control cabinet door, 17-replaceable panel, 18-human-machine operation interface HMI, 19-keyboard mouse.
Detailed Description
The technical solution of the present patent will be described in further detail with reference to the following embodiments.
Referring to fig. 1-3, a virtual debugging system for a multifunctional production line and equipment comprises a hardware part 1 and a software part 2, wherein the hardware part 1 comprises a frame 10, adjustable foot pads are installed at four corners of the bottom of the frame 10, the adjustable foot pads can enable the whole equipment to be more stable when being placed, and avoid shaking, side plates 11 are arranged on the left side and the right side of the frame 10, the side plates 11 play a role in protection, a back plate is also installed on the back of the frame 10 and also plays a role in protection, a display 12 is embedded in the upper half of the frame 10 and is a fully transparent display screen, visual impact is effectively improved, eyes are prevented from being injured, the display 12 is used for displaying a digital prototype model and the running state thereof, a three-color signal lamp post 13 is arranged at the top of the frame 10, and the three-color signal lamp post 13 is used for displaying the running state of, different alarm prompt information is given, a computer host is further arranged inside the rack 10 and used for running simulation software and processing communication between the mechanical part and the software part;
the front side of the lower part of the rack 10 is also provided with a control cabinet 14, an air switch, a contactor, a relay, a frequency converter, a signal converter module, a servo driver, a stepping driver, an exchanger and a wiring terminal are arranged in the control cabinet 14, rollers 15 are arranged at the bottom of the control cabinet 14, the control cabinet 14 is convenient to move, a control cabinet door 16 is hinged to the front side of the control cabinet 14, the control cabinet 14 is used for system power supply and drive control of various motors, the signal converter module is mainly used for butting a virtual sensor signal in a digital model to a real PLC (programmable logic controller), and meanwhile, the signal converter module can be used for programming electrical behaviors such as a simulation motor driver, an encoder and the frequency converter;
the top of switch board 14 is equipped with removable panel 17, switch board 14 and removable panel 17 pass through the signal line and the connection of inserting by plane, in order to carry out the transmission of signal, the embedding is installed man-machine operation interface HMI18 on the removable panel 17, still be equipped with servo motor on the removable panel 17, step motor, ordinary motor, variable frequency speed control motor, voltage current sensing, temperature and humidity sensing, photoelectric switch, proximity switch, PLC and IO module, rotary switch, reset button, emergency stop button, relay and binding post, PLC on the removable panel 17, HMI, signal converter module and computer pass through switch and net twine connection, data interaction between the three, servo motor divide into two kinds of different control modes of pulse and communication, step motor divide into two kinds of different control modes of pulse and analog quantity, all kinds of sensors and button: and transmitting the signals to a PLC controller for data acquisition training, and simultaneously performing signal association with a sensor in a digital model to realize functions of troubleshooting of equipment and the like. The control cabinet 14 in the hardware part 1 comprises a universal part and a replaceable part, the universal part is used for general training of routine electric elements and sensors, programming and debugging of a servo motor, a PLC (programmable logic controller) and an HMI (human machine interface), the replaceable part is used for wiring, program debugging and troubleshooting training of a specific digital prototype, the hardware part 1 is provided with a VR (virtual reality) interface and can be connected with wearable equipment to carry out debugging and teaching, and the hardware part 1 can also carry out operations of rotation, amplification, translation and the like on a model in the software part 2 through a 3D (three-dimensional) mouse.
The software part 2 comprises equipment simulation software, PLC and HMI simulation software, a plurality of sets of digital prototype models and communication interface programs, the controllers in the software part 2 and the hardware part 1 exchange data by adopting communication protocols such as OPC, TCP/IP and the like, bidirectional transmission of signals can be realized, virtual sensor signals can be transmitted to real PLC input points by connecting a signal processing module, the software part 2 also comprises related communication interface programs for secondary development, and the robot model can be directly connected with third party off-line programming software to perform virtual debugging of the robot and comprises related communication interface programs for secondary development, and can also be connected with a real robot demonstrator and the controller to perform virtual debugging.
Referring to fig. 4, a working process of the virtual debugging system for the multifunctional production line and the equipment is as follows:
1) electrical wiring; finishing the wiring work of the replaceable panel according to the provided wiring schematic diagram;
2) importing a digital model: the equipment is electrified, a digital prototype model or a robot model to be programmed and debugged is introduced into simulation software of a single piece of equipment, a plurality of digital prototype models can be introduced, and the models can be switched through the simulation software;
3) writing a program for control: writing a control program and a man-machine operation interface program of a digital prototype to be controlled in PLC and HMI programming software, and creating program variables (including a docking signal variable with the digital prototype) in the programming process;
4) communication connection configuration: firstly, connecting a PLC, an HMI, a signal converter module and a computer host through a network cable and an exchanger; then, correlating the virtual sensor signal of the digital model and the control signal of the execution component and the like with the PLC program variable through an OPC or TCPIP communication protocol in simulation software; finally, carrying out communication test to ensure that the connection has no errors;
5) virtual debugging: firstly, downloading programs of a PLC and an HMI to corresponding hardware, enabling the hardware to be in an operating state, then starting simulation software, debugging a digital prototype model through the HMI human-computer interaction device, and observing the operating state of the digital prototype model.
6) Optimizing and debugging the model: judging whether the digital model of the control program or the prototype is modified according to the result of the step 5), if 5) the operation result does not reach the expectation, returning to the step 2) again to load the modified model, simultaneously modifying and perfecting the program in the step 3), and debugging the model again through 4) and 5) until the operation of the program and the digital prototype reaches the expected effect,
7) troubleshooting training of equipment: and downloading a professional troubleshooting program and a troubleshooting digital prototype model in the PLC, and then starting debugging the digital prototype model. On the premise of sensor faults, program parameter setting errors, mechanical positioning faults, mechanical interference and other faults, the model cannot normally operate. Firstly, positioning the fault, finding out the fault point of the equipment, then repairing the fault point (performing corresponding operation on the replaceable panel or performing corresponding setting in the program and simulation software according to a manual), and finally debugging the digital prototype model again until the fault is eliminated.
8) Virtual debugging of a production line: loading a digital prototype model corresponding to a station to each single machine equipment manually or in a program control mode according to the station composition and layout of a production line; virtually debugging each single machine device; physically connecting a plurality of single-machine equipment with a switch through a network cable; the virtual debugging, model optimizing debugging and troubleshooting training process of the production line is similar to that of single-machine equipment, and the debugging and troubleshooting working process of the single-machine equipment is referred.
9) And (3) production line data acquisition and display, wherein the PLC of each stand-alone device is connected through Scada software to acquire data of each device, and the acquired data can be displayed through commercial Scada configuration software or a window interface developed by the commercial Scada configuration software by self through a high-level language. And uploading to the cloud platform through the gateway of the Internet of things.
The system has the following characteristics:
1. the system can map the virtual sensor signal to an input DI point of a real PLC, the digital quantity input DI of the PLC is determined by an external physical sensor signal, and the traditional simulation software cannot directly correspond the virtual sensor to the input DI of the real PLC.
The implementation mode is two types: the main difference is that one uses the existing PLC hardware and the other uses a specially developed signal converter module.
A) The method is realized by adding a PLC (programmable logic controller) 1, firstly, the virtual sensor signals of the simulation software are docked to an alterable data storage area of the PLM1, then the data in the data storage area is mapped to a digital quantity output DO point of the PLC1 through a program, then the corresponding DO point signals of the PLC1 are connected to a digital quantity input DI point of the PLC2 receiving the signals through a hardware connection mode, and therefore the input of the virtual sensor signals of the simulation software to the PLC2 is completed.
B) And adding a signal converter module and a communication algorithm to enable the virtual sensor signal to reach a real PLC input DI point. The converter module is provided with an input/output DI module and a DO module, a chip is internally provided with a memory, and the converter module is provided with a CPU and can run a software algorithm. The realization process is as follows: firstly, virtual sensing signals of simulation software are butted to a data storage area of a signal converter module, then data in the data storage area are mapped to a digital quantity output DO point of the signal converter module through a program, and then a corresponding DO point signal of the signal converter module is connected to a digital quantity input DI point of a PLC (programmable logic controller) receiving the signal through a hardware connection mode, so that the input of the virtual sensing signals of the simulation software to the PLC is completed.
2. The system has an electrical behavior simulation function. The debugging of the traditional electrical equipment into the equipment such as a motor, an electromagnetic valve, an encoder, a frequency converter and the like needs the cooperation of PLC hardware and corresponding equipment hardware to complete. The system can simulate the behaviors of a real motor, an electromagnetic valve, an encoder and a frequency converter, and a debugging process is completed in a mode of combining PLC with software. The debugging of the PLC program is no longer dependent on mechanical hardware.
The implementation method comprises the following steps: and the communication process of the PLC, a motor driver, an electromagnetic valve, an encoder and a frequency converter is simulated by a program by adding PLC hardware or a signal converter module. And decoding the data input by the PLC according to the communication protocol, and simultaneously transmitting the result data back to the PLC, so that the PLC mistakenly thinks that the real equipment is connected and can continuously finish debugging.
3. The system can realize simulation debugging of the servo motor and the stepping motor without special processing of a PLC servo or stepping motor control program. Because the traditional simulation software is difficult to realize the transmission of the virtual sensing signal to the real PLC output DI, the origin point returning process of a servo or stepping motor cannot be finished. In addition, the traditional simulation software is difficult to realize the simulation of the communication principle of the driver and the PLC.
The implementation mode is as follows: virtual commissioning of servos and stepper motors can be achieved with the techniques in 1 and 2.
4. The system can be connected with third-party robot off-line programming software or demonstrator hardware to perform virtual debugging of robot programs.
The implementation mode is as follows: through the development of related communication interface programs (through OPC protocols or TCPIP or MODBUS TCP and other protocols), the connection with third-party offline programming software or demonstrator hardware is realized. And correlating the robot joint data in the simulation software with the joint data of the robot calculated in third-party offline programming software or a demonstrator. The robot real demonstrator mentioned here integrates a controller of the robot, and needs to be programmed and set to shield signals of a real encoder or a sensor, so that the phenomenon that the demonstrator generates an alarm because the real driver is not connected is avoided.
5. A plurality of single devices can be connected through a network cable to form a virtual production line, and debugging of the virtual production line is completed.
The implementation mode is as follows: and respectively downloading different station scene models of the production line to corresponding single-machine equipment, and arranging the equipment according to the technological process. Through the signal transmission of adjacent equipment, realize the material transmission between different equipment. After the material reaches the appointed position of the front equipment, a material in-place signal is generated, the signal is transmitted to the rear equipment through a TCP IP or OPC protocol, the rear equipment receives the signal and then sends the received signal to the front equipment, the disappearance of the material of the front equipment is controlled through a simulation software program, and meanwhile the material is generated at the appointed position by the rear equipment, so that the material transmission is realized.
6. The teaching scheme and resources corresponding to the matched model are different from the conventional teaching scheme and resources, and the functions which cannot be realized by the traditional equipment are realized based on the virtual debugging equipment fault removal teaching mode
7. Each virtual mechanical model has a programming and model optimization method, and the plc algorithm program of each virtual mechanical model is used for realizing the functions which are difficult to realize by original software by writing the program.
8. The system can simulate various types of virtual sensors, the states and operation data of virtual equipment can be displayed through collection and monitoring,
the implementation mode is as follows: firstly, virtual sensor signals are set in simulation software and a signal converter module, signal format conversion is carried out on complex sensors (such as an encoder and temperature sensing), and actual physical signals are converted into a data format which can be received by a PLC. The PLC controllers corresponding to the virtual debugging system equipment are connected through Scada software or an Internet of things gateway, and the driver corresponding to the PLC is contained in the Scada software or the Internet of things gateway, so that communication connection can be established with the PLC, and running data of the virtual sensor and other parts can be acquired. The Scada software can configure pictures, display the acquired data and monitor the equipment. Or the data is uploaded to the cloud end through the internet of things gateway and is pushed to the mobile phone App through the network, and the running state of the equipment is monitored.
9. The system does not depend on a mechanical body, can load and edit various scene models, carries out virtual debugging of various devices,
the implementation mode is as follows: the digital model can be imported in a U disk insertion mode, can be directly loaded through a file server, can be downloaded to the local from a network server through the Internet, and then is loaded. The simulation software can edit the digital model and also can switch the digital model. And loading different digital models aiming at different industrial scenes, downloading corresponding control programs in the PLC, and carrying out virtual debugging on various devices.
Although the preferred embodiments of the present patent have been described in detail, the present patent is not limited to the above embodiments, and various changes can be made without departing from the spirit of the present patent within the knowledge of those skilled in the art.
Claims (7)
1. A virtual debugging system of a multifunctional production line and equipment comprises a hardware part (1) and a software part (2), and is characterized in that the hardware part (1) comprises a rack (10), the front side of the lower part of the rack (10) is also provided with a control cabinet (14), and a human-machine operation interface HMI (18) is embedded and installed on a replaceable panel (17);
the control cabinet (14) in the hardware part (1) comprises a universal part and a replaceable part, the universal part is used for general training of conventional electric elements and sensors, servo motors, PLC (programmable logic controller), HMI (human machine interface) programming and debugging and the like, the replaceable part is used for wiring, program debugging and troubleshooting training aiming at a specific digital prototype, the hardware part (1) is provided with a VR (virtual reality) interface and can be connected with wearable equipment to carry out debugging and teaching, and the hardware part (1) can also carry out operations of rotation, amplification, translation and the like on a model in the software part (2) through a 3D (three-dimensional) mouse;
the software part (2) comprises equipment simulation software, PLC and HMI simulation software, a plurality of sets of digital prototype models and communication interface programs, the controllers in the software part (2) and the hardware part (1) adopt communication protocols such as OPC, TCP/IP and the like to carry out data exchange, bidirectional signal transmission can be realized, virtual sensor signals can be transmitted to real PLC input points by connecting a signal processing module, the software part (2) also comprises related communication interface programs for secondary development, the robot model can be directly connected with third-party offline programming software to carry out virtual debugging of the robot, the related communication interface programs for secondary development are included, and a real robot demonstrator and the controller can be connected to carry out virtual debugging.
2. The virtual debugging system of multifunctional production line and equipment as claimed in claim 1, wherein: the adjustable foot pads are arranged at the four corners of the bottom of the frame (10), the adjustable foot pads can enable the whole equipment to be more stable when being placed, the shaking condition is avoided, the left side surface and the right side surface of the frame (10) are provided with side plates (11), the side plates (11) play a role in protection, the back of the frame (10) is also provided with a back plate which also plays a role in protection, the intelligent digital prototype testing machine is characterized in that a display (12) is embedded in the upper half part of the rack (10), the display is a (12) full-transparent display screen, the display (12) is used for displaying a digital prototype model and the running state of the digital prototype model, a three-color signal lamp post (13) is arranged at the top of the rack (10), the three-color signal lamp post (13) is used for displaying the running state of the digital prototype and giving different alarm prompt information, a computer host is further arranged inside the rack (10) and used for running simulation software and processing communication between the mechanical part and the software part.
3. The virtual debugging system of multifunctional production line and equipment as claimed in claim 1, wherein: the bottom of switch board (14) is equipped with gyro wheel (15), conveniently removes switch board (14), and articulated the installing of front side of switch board (14) has switch board door (16), and switch board (14) are used for the system power supply, the drive control of all kinds of motors, and signal converter module wherein mainly used is docked real PLC controller with the virtual sensor signal among the digital model on, simultaneously, can be used for programming simulation motor drive, electrical behavior such as encoder and converter.
4. The virtual debugging system of multifunctional production line and equipment as claimed in claim 1, wherein: the intelligent control cabinet is characterized in that an air switch, a contactor, a relay, a frequency converter, a signal converter module, a servo driver, a stepping driver, an exchanger and a wiring terminal are arranged in the control cabinet (14), a replaceable panel (17) is arranged at the top of the control cabinet (14), and the control cabinet (14) and the replaceable panel (17) are connected through a signal line and an aerial plug so as to transmit signals.
5. The virtual debugging system of multifunctional production line and equipment as claimed in claim 1, wherein: still be equipped with servo motor, step motor, ordinary motor, variable frequency speed control motor, voltage current sensing, temperature and humidity sensing, photoelectric switch, proximity switch, PLC and IO module, knob switch, reset button, scram button, relay and binding post on removable panel (17), all kinds of sensors and button carry out signal transmission to the PLC controller for data acquisition trains, and the sensor in the while and the digital model carries out signal correlation, in order to realize functions such as equipment troubleshooting.
6. The virtual debugging system of multifunctional production line and equipment as claimed in claim 6, wherein: the PLC, the HMI and the signal converter module on the replaceable panel (17) are connected with the computer host through the switchboard and the network cable, and data interaction is carried out among the PLC, the HMI and the signal converter module.
7. The virtual debugging system of multifunctional production line and equipment as claimed in claim 6, wherein: the servo motor is divided into two different control modes of pulse and communication, and the stepping motor is divided into two different control modes of pulse and analog quantity.
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| CN113570931A (en) * | 2021-07-29 | 2021-10-29 | 厦门凤凰创壹软件有限公司 | Intelligent PLC experimental box capable of controlling three-dimensional virtual simulation intelligent manufacturing production line |
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| CN207799371U (en) * | 2018-03-07 | 2018-08-31 | 上海晓奥汽车销售有限公司 | A kind of Virtual Debugging platform for Virtual Debugging system |
| CN110189567A (en) * | 2019-05-08 | 2019-08-30 | 上海飒智智能科技有限公司 | A kind of the industrial robot training system and Training Methodology of actual situation combination |
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