CN111985111A - Interpolation data-based production line multi-unit real-time synchronous simulation method and system - Google Patents
Interpolation data-based production line multi-unit real-time synchronous simulation method and system Download PDFInfo
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Abstract
The invention discloses a production line multi-unit real-time synchronous simulation method and system based on interpolation data, belonging to the field of virtual simulation and computer assistance and comprising the following steps: establishing a simulation model for each production unit on the production line independently, wherein the simulation model is used for describing the surface geometric shape and the motion state of the production unit; writing interpolation data into a pre-established public buffer area by using a write-in thread according to a preset write-in frequency; for each production unit, respectively reading interpolation data from the public buffer area by using a simulation thread after the interpolation data writing is finished each time, importing a corresponding simulation model, and simulating the motion state of the production unit; the motion state of the whole production line is simulated by simulating the motion state of each production unit. The invention can realize accurate, multi-unit separable and real-time synchronous production line simulation.
Description
Technical Field
The invention belongs to the field of virtual simulation and computer assistance, and particularly relates to a production line multi-unit real-time synchronous simulation method and system based on interpolation data.
Background
In order to improve the application level of the machining technology of the numerical control production line, reduce risks in the machining process of the production line and improve the accuracy of synchronous control of the production line, a great deal of research work is carried out on the simulation technology of the numerical control production line both domestically and abroad. The motion state of the whole production line is simulated in a computer by using a virtual simulation technology, so that engineering personnel can be helped to avoid a lot of risks of interference and collision before formal processing, and meanwhile, the whole processing flow can be optimally designed by analyzing engineering. Therefore, the method has very important theoretical significance and economic benefit for the synchronous virtual simulation research of the production line.
The traditional production line simulation system combines all flows of production lines together to ensure the processing synchronism, but the mutual influence of each production line is larger, and the difficulty of independently observing a certain link is increased.
Disclosure of Invention
Aiming at the defects and improvement requirements of the prior art, the invention provides a production line multi-unit real-time synchronous simulation method based on interpolation data, aiming at solving the technical problems of larger mutual influence of production lines and high difficulty in observing a certain link independently in the existing production line simulation method and realizing the time synchronization of a simulation process and a real process to restore the site.
To achieve the above object, according to one aspect of the present invention, there is provided a method for multi-unit real-time synchronous simulation of a production line based on interpolation data, comprising:
establishing a simulation model for each production unit on the production line independently, wherein the simulation model is used for describing the surface geometric shape and the motion state of the production unit;
writing interpolation data into a pre-established public buffer area by using a write-in thread according to a preset write-in frequency;
for each production unit, respectively reading interpolation data from the public buffer area by using a simulation thread after the interpolation data writing is finished each time, importing a corresponding simulation model, and simulating the motion state of the production unit;
the motion state of the whole production line is simulated by simulating the motion state of each production unit.
The invention combines computer multithreading technology and object-oriented thinking, models each production unit on the production line independently, utilizes independent simulation threads to simulate the single production unit, controls the whole simulation process by controlling the writing frequency and the position of the writing thread, and leads the data to be synchronous with the actual working scene when reading the data. Therefore, the invention realizes accurate, multi-unit separable and real-time synchronous production line simulation.
Furthermore, the size of the public buffer area is the sum of the sizes of the memory spaces occupied by a group of interpolation data required by the motion of each production unit; the common buffer area is directly refreshed by the writing thread when the interpolation data are written in each time, and all the interpolation data in the common buffer area are directly read by each simulation thread when the interpolation data are read in each time; the execution logic of the write thread and the emulation thread can thereby be simplified.
Further, the interpolation data is obtained by sampling from the production line on site, or is obtained from the production unit in real time.
In the invention, interpolation data is set to be the interpolation data sampled from the production line site, and the production line site can be restored by off-line simulation; the interpolation data is set to be the interpolation data acquired from the production unit in real time, and real-time field simulation can be achieved. Therefore, the invention can not only restore the site, but also realize real-time site simulation, and has good adaptability.
Further, the invention provides a production line multi-unit real-time synchronous simulation method based on interpolation data, which further comprises the following steps: and when the interpolation data is obtained by sampling from the production line on site, the control of the whole production line simulation process is realized by controlling the writing frequency and position of the writing thread.
Further, when the interpolation data is obtained by sampling from the production line, the simulation of the motion state of the production line and the actual motion process of the production line are in an isochronal ratio relationship by controlling the writing frequency and position of the writing thread.
When the off-line simulation is carried out on the site, the writing frequency and the position of the writing thread are controlled, so that the relation between the simulation and the actual motion process of the production line is guaranteed in an isocratic mode, and the real-time performance of the simulation can be guaranteed.
Further, for any production unit, the method for establishing the simulation model comprises the following steps:
establishing a 3D model for each part in the production unit, wherein the 3D model is used for describing the surface geometry of the corresponding part;
grouping the 3D models of the parts in the production unit according to the motion state, so that the 3D models of the parts with the same motion state are divided into the same group;
initializing a kinematic chain model of the production unit according to the component grouping result, and correspondingly adding the grouped 3D model components into a kinematic chain node according to the corresponding production unit;
and storing the motion state of each motion chain node into the motion node according to the motion characteristic of the production unit, thereby completing the establishment of the simulation model of the production unit.
Further, the motion state includes: motion mode, motion reference axis, and motion axis limits.
Further, the invention provides a production line multi-unit real-time synchronous simulation method based on interpolation data, which further comprises the following steps: and the simulation of the motion state of the production line is assisted by externally hanging a functional thread which uses interpolation data as input.
The invention can use the interpolation data as the input functional thread by plug-in, and realizes the function expansion while ensuring the integrity and independence of the original functions, therefore, the invention has good expandability.
Further, the invention provides a production line multi-unit real-time synchronous simulation method based on interpolation data, which further comprises the following steps:
in the process of simulating the motion state of the whole production line, if the risk is monitored, the simulation thread of the production unit with the risk is independently operated after the production unit with the risk is positioned, so that the motion state of the production unit with the risk is analyzed according to the simulation result.
According to another aspect of the present invention, there is provided a production line multi-unit real-time synchronous simulation system based on interpolation data, comprising: the device comprises a modeling module, a writing module and N simulation modules; n represents the total number of the production units in the production line, and the N simulation modules correspond to the N production units in the production line one by one;
the modeling module is used for independently establishing a simulation model for each production unit on the production line and correspondingly storing the simulation models into the N simulation modules; the simulation model is used for describing the surface geometry and the motion state of the production unit;
the writing module is used for writing interpolation data into a pre-established public buffer area by using a writing thread according to a preset writing frequency;
each simulation module is used for reading the interpolation data from the public buffer area after the interpolation data is written into the corresponding production unit by using a simulation thread, importing a corresponding simulation model and simulating the motion state of the production unit.
Generally, by the above technical solution conceived by the present invention, the following beneficial effects can be obtained:
(1) the invention combines computer multithreading technology and object-oriented thinking, models each production unit on the production line independently, utilizes independent simulation threads to simulate the single production unit, controls the whole simulation process by controlling the write-in frequency and position of the write-in threads when the site is restored by off-line simulation, and leads the data to be synchronous with the actual working scene when reading data. Therefore, the invention realizes accurate, multi-unit separable and real-time synchronous production line simulation.
(2) The invention uses a single public cache region to cache the interpolation data, and all threads operate the public cache region, thereby not only reducing the multiplexing of data and saving the memory space, but also ensuring the utilization rate of each data, and avoiding the situation that a certain data can not be used at all.
(3) The invention adds new functional modules by using the plug-in thread mode, thereby ensuring the integrity and independence of the original functions and greatly improving the expansibility and the readability of each functional module. Meanwhile, the function realization of each module can not conflict with each other.
(4) The invention realizes the simulation of the motion state of a single production unit and the whole production line based on the threads, and because the threads are independent, the communication among the threads is less, so that the threads can be conveniently added or deleted, the switching between the monitoring of the whole production line and the monitoring of the single production unit is smooth, and the calculation time consumed by the communication among the processes can be reduced.
Drawings
FIG. 1 is a flowchart of a method for real-time synchronous simulation of multiple units of a production line based on interpolation data according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a production line multi-unit real-time synchronous simulation method based on interpolation data according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a machine tool component grouping provided by an embodiment of the invention;
fig. 4 is a schematic view of a kinematic chain model of a machine tool according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
In the present application, the terms "first," "second," and the like (if any) in the description and the drawings are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order.
Example 1:
a method for real-time synchronous simulation of multiple units of a production line based on interpolation data, as shown in fig. 1 and 2, includes:
establishing a simulation model for each production unit on the production line independently, wherein the simulation model is used for describing the surface geometric shape and the motion state of the production unit;
writing interpolation data into a pre-established public buffer area by using a write-in thread according to a preset write-in frequency;
for each production unit, respectively reading interpolation data from the public buffer area by using a simulation thread after the interpolation data writing is finished each time, importing a corresponding simulation model, and simulating the motion state of the production unit;
the motion state of the whole production line is simulated by simulating the motion state of each production unit.
In order to simplify the execution logic of the write-in thread and the simulation thread, as an optional implementation manner, in this embodiment, the size of the common buffer area is the sum of the sizes of the memory spaces occupied by a group of interpolation data required by the motion of each production unit; the common buffer area is directly refreshed by the writing thread when the interpolation data are written in each time, and all the interpolation data in the common buffer area are directly read by each simulation thread when the interpolation data are read in each time;
without loss of generality, taking a typical production unit, namely a machine tool as an example, in a multi-axis machine tool, one interpolation data is up to 6 floating point data, and because in the embodiment, one machine tool uses one interpolation data at a time and does not need the connection between the previous data and the next data, for one machine tool, the operation of the simulation process can be supported only by storing one machine tool interpolation data in a common cache region; the size of the memory space occupied by one floating point data is denoted by s, and the total number of production units in the production line is denoted by N, so that the size of the common cache area is N × 6 × s.
In this embodiment, the control of the whole production line simulation process is realized by controlling the write frequency and position of the write thread.
When the method is used for off-line simulation and site restoration, the interpolation data are correspondingly sampling interpolation data acquired from the site; in order to ensure the real-time performance and accuracy of the simulation, in this embodiment, the simulation of the motion state of the production line and the actual motion process of the production line are in an isochronal ratio relationship by controlling the write frequency and the write position of the write thread;
similarly, taking the machine tool as an example, the above isochronal ratio relationship is further explained:
when the machine tool actually moves, t1 is consumed when moving from the knife position a to the knife position b, t2 is consumed when moving from the knife position b to the knife position c, t3 is consumed when moving from the knife position a to the knife position b, and t4 is consumed when moving from the knife position b to the knife position c; in the present embodiment, t1: t2 ═ t3: t 4; therefore, the whole processing process is compressed according to the time proportion, the effect of a reduction processing field is achieved, and meanwhile, the mechanical processing simulation is conveniently expanded.
In this embodiment, for any production unit, the method for establishing the simulation model includes:
establishing a 3D model for each part in the production unit, wherein the 3D model is used for describing the surface geometry of the corresponding part; in this embodiment, the 3D model of each component is specifically a triangular plate model, the corresponding file format is stl, and the coordinates of the vertex of the triangular plate are described in the stl file;
grouping the 3D models of the parts in the production unit according to the motion state, so that the 3D models of the parts with the same motion state are divided into the same group; the motion state comprises: a motion mode, a motion reference axis, and a motion axis limit; the movement mode includes: linear motion along an axis or rotation around the axis;
initializing a kinematic chain model of the production unit according to the component grouping result, and correspondingly adding the grouped 3D model components into a kinematic chain node according to the corresponding production unit;
storing the motion state of each motion chain node into the motion node according to the motion characteristic of the production unit, thereby completing the establishment of a simulation model of the production unit;
also taking a machine tool as an example, in a general multi-axis numerical control machine tool, the machine tool can be divided into 7 parts at most according to the motion state: the machine tool comprises a machine tool base part, an X-axis moving part, a Y-axis moving part, a Z-axis moving part, an A-axis moving part, a B-axis moving part and a C-axis moving part; the AC cradle five-axis machine tool shown in fig. 3, without B-axis, therefore, comprises 6 motion parts, and accordingly, the 3D model of the part is divided into 6 groups, Base in fig. 3 being the Base, X, Y, Z, A, C representing five axes respectively;
the kinematic chain model of the production unit describes the motion state of each component in the production unit, and the kinematic chain model of the production unit is constructed, so that the mutual motion relationship among the components can be described, a transformation matrix is obtained, and the transformation relationship (namely a mathematical expression) of the tail end of the kinematic chain relative to the starting end of the kinematic chain can be obtained, so that the mutual linkage of each component is realized, and the desired motion is obtained;
for the AC cradle five-axis machine tool shown in fig. 3, the kinematic chain model is established as shown in fig. 4, and similarly, Base in fig. 4 is the Base, X, Y, Z, A, C represents five axes, respectively, wherein the component transformation indicated by the arrow would drive the pointed component to make the same transformation, for example: the axis A moves, the axis C moves along with the axis A, the mutual transformation relation can be expressed by establishing a kinematic chain model, and then the transformation relation of the terminal coordinate system relative to the workpiece coordinate system is solved.
In order to implement function expansion, this embodiment further includes: the simulation of the motion state of the production line is assisted by externally hanging a functional thread using interpolation data as an input, for example, an interference check thread using interpolation data, a machining simulation thread using interpolation data, a motion state monitoring thread, and the like.
The present embodiment implements simulation of motion states of a single production unit and an entire production line based on threads, for example, for the machine tool 1 and the machine tool 2 in fig. 2, corresponding simulation threads are respectively created; because mutual independence between the thread, the thread that can be very convenient adds or subtracts for it is smooth with the switching of monitoring single production unit to monitor whole production line, and based on above-mentioned advantage, this embodiment still includes:
in the process of simulating the motion state of the whole production line, if the risk is monitored, the simulation thread of the production unit with the risk is independently operated after the production unit with the risk is positioned, so that the motion state of the production unit with the risk is analyzed according to the simulation result.
Example 2:
the embodiment is similar to embodiment 1, except that the embodiment is used for real-time field simulation, and accordingly, in the embodiment, the interpolation data is real-time interpolation data of a machine tool.
Example 3:
a production line multi-unit real-time synchronous simulation system based on interpolation data comprises: the device comprises a modeling module, a writing module and N simulation modules; n represents the total number of the production units in the production line, and the N simulation modules correspond to the N production units in the production line one by one;
the modeling module is used for independently establishing a simulation model for each production unit on the production line and correspondingly storing the simulation models into the N simulation modules; the simulation model is used for describing the surface geometry and the motion state of the production unit;
the writing module is used for writing interpolation data into a pre-established public buffer area by using a writing thread according to a preset writing frequency;
each simulation module is used for reading the interpolation data from the public buffer area after the interpolation data is written in each time by utilizing a simulation thread for the corresponding production unit, importing a corresponding simulation model and simulating the motion state of the production unit;
in this embodiment, the detailed implementation of each module may refer to the description in the above method embodiment, and will not be repeated here.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A production line multi-unit real-time synchronous simulation method based on interpolation data is characterized by comprising the following steps:
establishing a simulation model for each production unit on the production line independently, wherein the simulation model is used for describing the surface geometry and the motion state of the production unit;
writing interpolation data into a pre-established public buffer area by using a write-in thread according to a preset write-in frequency;
for each production unit, respectively reading interpolation data from the public buffer area by using a simulation thread after the interpolation data writing is finished each time, importing a corresponding simulation model, and simulating the motion state of the production unit;
the motion state of the whole production line is simulated by simulating the motion state of each production unit.
2. The interpolation data-based production line multi-unit real-time synchronous simulation method as claimed in claim 1, wherein the size of the common buffer area is the sum of the sizes of memory spaces occupied by a group of interpolation data required by the motion of each production unit;
and the common buffer area is directly refreshed by the writing thread when the interpolation data is written in each time, and all the interpolation data in the common buffer area are directly read by each simulation thread when the interpolation data is read in each time.
3. The interpolation data-based production line multi-unit real-time synchronous simulation method as claimed in claim 1, wherein the interpolation data is interpolation data sampled from a production line on site or interpolation data acquired from a production unit in real time.
4. The interpolation data-based production line multi-unit real-time synchronous simulation method of claim 3, further comprising:
and when the interpolation data are obtained by sampling from the production line on site, the control of the whole production line simulation process is realized by controlling the writing frequency and position of the writing thread.
5. The method as claimed in claim 4, wherein when the interpolated data is sampled from the production line, the writing frequency and position of the writing thread are controlled to make the simulation of the motion state of the production line and the actual motion process of the production line have an isochronal ratio relationship.
6. The interpolation data-based production line multi-unit real-time synchronous simulation method of claim 1, wherein the method for establishing the simulation model of any production unit comprises the following steps:
establishing a 3D model for each part in the production unit, wherein the 3D model is used for describing the surface geometry of the corresponding part;
grouping the 3D models of the parts in the production unit according to the motion state, so that the 3D models of the parts with the same motion state are divided into the same group;
initializing a kinematic chain model of the production unit according to the component grouping result, and correspondingly adding the grouped 3D model components into a kinematic chain node according to the corresponding production unit;
and storing the motion state of each motion chain node into the motion node according to the motion characteristic of the production unit, thereby completing the establishment of the simulation model of the production unit.
7. The interpolation data-based production line multi-unit real-time synchronous simulation method as claimed in claim 6, wherein the motion state comprises: motion mode, motion reference axis, and motion axis limits.
8. The interpolation data-based production line multi-unit real-time synchronous simulation method of any one of claims 1 to 7, further comprising: and the simulation of the motion state of the production line is assisted by externally hanging a functional thread which uses interpolation data as input.
9. The interpolation data-based production line multi-unit real-time synchronous simulation method of any one of claims 1 to 7, further comprising:
in the process of simulating the motion state of the whole production line, if the risk is monitored, the simulation thread of the production unit with the risk is independently operated after the production unit with the risk is positioned, so that the motion state of the production unit with the risk is analyzed according to the simulation result.
10. A production line multi-unit real-time synchronous simulation system based on interpolation data is characterized by comprising: the device comprises a modeling module, a writing module and N simulation modules; n represents the total number of the production units in the production line, and the N simulation modules correspond to the N production units in the production line one by one;
the modeling module is used for independently establishing a simulation model for each production unit on the production line and correspondingly storing the simulation models into the N simulation modules; the simulation model is used for describing the surface geometry and the motion state of the production unit;
the writing module is used for writing interpolation data into a pre-established public buffer area by using a writing thread according to a preset writing frequency;
each simulation module is used for reading the interpolation data from the public buffer area after the interpolation data is written into the corresponding production unit by using a simulation thread, importing a corresponding simulation model and simulating the motion state of the production unit.
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