JP2002068416A - Simulation method for carrying system including a plurality of devices constituting work carrying path, and simulator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simulate the operation of a carrying system on a level corresponding to an actual machine. SOLUTION: A simulation executing part 50 generates a model showing a device to which a work belongs, discriminates a device element of the device such as a behavior of a tool and discriminates a work action state from the presence or absence of a mutual action between the work and the device element or between the work and another work and a discrimination rule fixed in advance based on data inputted from a data inputting part 10 of a simulator and showing shape and dimension of each device for the carrying system, a behavior of the device element and a control logic, and simulates the work and the behavior of the device element in the device model of the carrying system based on a work action state and the behavior of the tool.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for simulating a transfer system and a simulator for implementing the method, and more particularly to a simulation for performing a three-dimensional simulation of a workpiece transfer state in a mechanical transfer mechanism of a transfer system at a level equivalent to a real machine. The present invention relates to a method and a simulator.

[0002]

2. Description of the Related Art A transfer system includes a mechanical transfer mechanism including a plurality of transfer apparatuses having a conveyor, a pusher, and the like. The transfer mechanism is controlled under the control of, for example, a programmable controller (hereinafter, referred to as a PLC). It works. Generally, the design of such a system is performed in cooperation with a mechanical engineer and a software engineer. For example, based on machine specifications and operation specifications designed by a mechanical engineer, control specifications are determined under information exchange between the two engineers, and a software engineer designs and creates control software based on the control specifications.

Therefore, in the system design, it is necessary to examine the design specifications after sufficiently understanding the relationship between the machine specifications, the operation specifications, and the control specifications. The operation of the entire machine is complicated in a machine in which the devices operate in complex cooperation with each other. On the other hand, information exchange between a mechanical engineer and a software engineer is usually performed based on documents and drawings, and it is difficult for both to grasp the design specification to a detailed level. Accordingly, it is necessary to repeatedly design each part of the machine until the design specifications of each part of the machine are finally determined so that the entire machine can exhibit the required performance, which requires a great deal of labor and time.
In particular, if the required performance and operation cannot be achieved by partially revising the control specifications, the machine specifications and operation specifications of the problematic device and the upstream device must be changed. Control specifications and control programs need to be significantly changed.

[0004] From the viewpoint of reducing the number of man-hours in system design, attempts have been made to simulate the operation of each part of a machine under design. For example, Japanese Patent Application Laid-Open No. 10-13373
No. 4 discloses a discrete simulator used for system design, test adjustment, and operation and maintenance.
According to this type of simulator, it is possible to find a bottleneck in distribution, and to perform a simple simulation such as a lead time, inventory management, and an operation rate.

[0005]

However, a conventional simulator represented by the above-mentioned publication simulates physical distribution equipment at the equipment cell level. When a system that operates in a three-dimensional or linked manner is to be simulated, the degree of detail of the simulation is insufficient.
In some cases, the system design cannot be fully supported.

The simple simulator described in the above publication is configured on the assumption that it is used together with a real machine PLC or a virtual machine having a PLC function, and inputs a sequence output from the PLC and outputs a simulation output to the PLC. It is something to do. For this reason, the control logic in the simple simulator is expressed in the PLC code format, and information exchange between the machine engineer and the software engineer is performed using information expressed in such a code format as a medium. Lacks practicality.

An object of the present invention is to provide a simulation method and a simulator capable of simulating a transfer system including a plurality of devices constituting a work transfer path at a level equivalent to a real machine.

[0008]

According to a first aspect of the present invention, there is provided a method for simulating a transfer system including a plurality of devices constituting a two-dimensional or three-dimensional work transfer path, the method comprising: A model representing the device to which the work belongs is generated based on the operation specifications and control logic of the transfer system, and the behavior of the device element of the device to which the work belongs is determined. Based on the presence or absence of an action and a predetermined discriminant rule, the work state of the work is determined, and based on the behavior of the device element and the work state of the work, the work behavior in the model is simulated together with the behavior of the device element. I do.

Each device element of the transport system mainly functions as a movable portion for driving a work, but some have other functions such as a stopper function. In addition, there is a movable unit that conveys a required number of works at a time, and in this case, the work is driven by the movable unit via another work. Further, the work may be in an operating state in which the work does not interact with the device element or another work, such as running free in the apparatus or freely falling between the apparatuses. As described above, the behavior of the work in the transfer system is affected not only by the behavior of the movable part of the apparatus, but also by the interaction between the work and the stationary part of the apparatus or another workpiece. Is difficult to grasp the work behavior.

In the simulation method of the present invention, when simulating the behavior of a work, in addition to the behavior of the device element, it is determined from the presence or absence of interaction between the work and each device element or another work, and from a predetermined discriminant rule. The work operation state is taken into consideration, and a work behavior in an actual machine with a complicated transition of the work operation state can be simulated. Also, when generating the model,
By using the basic data and the expression format suitable for the degree of detail required in the simulation, it is possible to execute the simulation with the level of detail equivalent to the actual machine.

Such a simulation at the level equivalent to the actual machine is performed based on the provisionally set design specifications even when the design specifications (mechanical specifications, operation specifications, and control specifications) of the transfer system are not determined. When the specification is determined, it can be implemented at any stage of the design based on the determined design specification. Then, based on the simulation result, it is possible to judge the suitability of each part of the design specification and make necessary corrections, so that the optimum design specification can be determined within a short period of time.

In the present invention, preferably, the working state of the work is a free state in which no interaction occurs between the work and the device element or another work, and a fixed state in which the work is driven by the device element or another work. The state is divided into a constraint state in which the work is restricted by the device element, and an interference state in which the work contacts or overlaps the operable device element or another work. Further, the predetermined discriminant rule defines a work operation state based on the action of the device element or another work on the work and its direction. For example, a predetermined discriminant rule is that whether the object interacting with the work is an apparatus element or another work, and whether the apparatus element interacting with the work or another work is upstream in the work moving direction in the work transfer path. A discriminant rule that determines that the work is in a fixed state or an interference state based on whether it is on the side or the downstream side, and determines that the work is in a restricted state if the work interacting with the device element is not in a fixed state It includes a discriminant rule and a discriminant rule that determines that the work is in a free state if the work is not in a fixed state, an interference state, or a restricted state.

In this preferred embodiment, the working state of the work can be properly determined, and the simulation of the work behavior according to the actual machine can be performed. Preferably, in the simulation method of the present invention, a model representing at least a part of the device to which the workpiece belongs and the upstream and downstream devices thereof is generated. In this preferred embodiment, the work state of the work is determined based on the behavior of these device elements, the presence or absence of interaction between the work and each device element or another work, and a predetermined discriminant rule, and further the simulation of the work behavior is performed. Done.

According to this preferred aspect, it is possible to simulate the behavior of the work including the transfer of the work between the apparatuses. Preferably, in the simulation method of the present invention,
A model is generated that includes the sensor of the device to which the workpiece belongs, more preferably the sensor of the device to which the workpiece belongs, and the sensors of the upstream and downstream devices. Then, a sensor output is generated for the control logic when the workpiece interacts with the sensor.

According to this preferred embodiment, it is not necessary to use the sensor output of the actual machine at the time of the simulation, and the simulation can be carried out only by a system independent of the actual machine. Removes the constraint that the sensor output should be represented by.
As a result, there are no restrictions on the description format of the machine specifications, operation specifications, and control logic used in the simulation, and the description can be made in, for example, a natural language or a similar format. Along with this, it is possible to use control specifications written in natural language, for example, Japanese, for information exchange between mechanical engineers and software engineers during the design process of the transport system, and Communication is facilitated, and both hardware and software design can be completed in a short time.

According to a sixth aspect of the present invention, there is provided a simulator for simulating a transfer system including a plurality of devices constituting a two-dimensional or three-dimensional work transfer path, wherein the model data represents the shape and dimensions of each device. A data input unit for inputting simulation data including behavior data representing behavior of device elements of each device and logic data representing control logic for each device; a data storage unit for storing simulation data for each device; A simulation control input unit for selecting simulation data for the device to which the device belongs, a simulation execution unit for performing simulation, and a simulation result confirmation unit for recording a result of the simulation executed by the simulator execution unit. The model execution unit generates a model representing the device to which the work belongs based on the model data selected by the simulation control input unit, and a behavior generation unit and a logic data based on the behavior data and the logic data selected by the simulation control input unit. A device element behavior processing unit that determines the behavior of the device element of the device to which the work belongs; and the action state of the work based on the presence or absence of interaction between the work and the device element or another work and a predetermined discriminant rule. Determining, further including a work behavior processing unit that determines the behavior of the work based on the action state of the work and the behavior of the device element, wherein the behavior of the work in the model is simulated together with the behavior of the device element. I do.

According to the simulator of the present invention, the work and the device element (particularly, the device movable portion) are taken into account at the level of detail equivalent to the actual machine by using the data and the expression form adapted to the required detail level while taking into account the work operation state. Behavior can be simulated. Further, based on the recording of the simulation result, the simulation result can be displayed in the form of, for example, a three-dimensional image or character information, or can be displayed as a three-dimensional moving image. By examining the design specifications at various stages of design based on such a display, the optimum design specifications of the transport system can be determined within a short period of time.

In the simulator according to the present invention, preferably, the simulation execution unit divides the working state of the work into a free state, a fixed state, a constraint state, and an interference state. Further, the simulation executing unit generates a model representing at least a part of the device to which the workpiece belongs and the upstream and downstream devices thereof. Further, a model including a sensor of the device to which the workpiece belongs and a sensor of the device on the upstream side and the downstream side is generated, and when the workpiece interacts with one or more sensors, a sensor output is generated and output to the control logic. You may do it. Preferably, the logic data is input to the data input unit in a logical expression format using a natural language.

The simulator according to the preferred embodiment can sufficiently support the design of the transport system by performing a simulation in conformity with the actual machine, and can reduce the restriction on the description format of the data to be provided at the time of the simulation to shorten the design period. Contribute.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A simulator of a transport system according to one embodiment of the present invention will be described below. The simulator of the present embodiment is intended to simulate a transport system, for example, a mechanical transport mechanism of a boxer. Although not shown in the drawings, the box packing machine can store, for example, 10 cigarette packs or packed products.
A parcel-packed product (carton) supplied from an exterior machine that packs individual items is packed into a cardboard box by a required number. The transport mechanism of the boxing machine is a large number of devices that operate in a three-dimensionally linked manner with each other. Consists of That is, the transport mechanism includes a device having a movable portion that moves linearly (uniaxially) such as a belt conveyor and a pusher, and a device having a stationary portion such as a stopper, and a complicated and three-dimensional transport path is configured as a whole in the transport mechanism. Is done. The parcel-packed product supplied from the exterior machine is packed in a cardboard box while being transported along this transport path.

The simulator of the present embodiment simulates the operation of each part of the transport mechanism to support the design of the transport mechanism of the box packing machine. For example, the simulator is constituted by a computer having various programs built therein. It has the functions of the following various functional units. The computer is a central processing unit that performs arithmetic and logical decisions related to the simulation, a storage device for storing data,
It has an input device such as a display device for displaying images and characters, a printer, a keyboard and a mouse used for data input by an operator, and the like.

As shown in FIG. 1, the simulator has a data input unit 10 for externally inputting or editing (hereinafter simply referred to as input) data required for the simulation.
And a data storage memory 20 for storing input data, and appropriately selecting data to be used for simulation from the stored data and setting simulation conditions (for example, conditions relating to simulation execution speed and occurrence of a pseudo event (for example, stop of any work)). And a simulation control condition storage memory 4 for storing data, simulation conditions, and the like.
0. Further, the simulator includes a simulation execution unit 50 for executing the simulation, a simulation result storage memory 60 for storing data representing the simulation result, and a simulation result confirmation unit 70 for recording and displaying the simulation result based on the simulation result data. .

This simulator is based on simulation data representing the machine specifications (shape dimensions), operation specifications (behavior) and control logic of each device of the transport system to be simulated, and the device elements in the device model, in particular, devices such as tools. It is intended to simulate the behavior of the workpiece together with the behavior of the movable part at a level equivalent to the actual machine. Therefore, in the simulation, whether there is any interaction (physical contact) between the workpiece and the device element (especially the movable part) or another workpiece And a work action state determined from a predetermined discriminant rule.
Further, input data to the simulator can be described in a natural language (for example, Japanese) or a format similar thereto. In other words, information can be exchanged between a mechanical engineer and a software engineer through a natural language in the process of designing a transport mechanism, particularly in determining control specifications.

In the simulation by the simulator having the above characteristics, each device of the transport mechanism is preferably modeled and displayed as, for example, a three-dimensional image together with the devices on the upstream side and the downstream side. It is represented by a device object roughly divided into an element, a work, and a sensor. Here, the device element refers to each unit of each device of the machine. For example, the device element refers to a device, a device operating unit (movable unit or stationary unit), an actuator of the device movable unit, and a tool mounted on the actuator and capable of contacting a workpiece.

In this embodiment, these device elements are specified by a tree-like hierarchical structure (a part of which is shown in FIG. 2). Specifically, each device element is identified by a symbol from the top of the tree hierarchy. It is expressed by connecting with "/". For example, the tool a mounted on the actuator a of the device a constituting the machine is “machine / device a / actuator a / tool a”.
It is expressed in the form.

Hereinafter, the various functional units of the simulator will be sequentially described in detail. The data input unit 10 is a device model input unit 11 for inputting model data representing the shape and dimensions of each unit of each device of the transport mechanism, and a behavior input for inputting behavior data representing the behavior (operation specifications) of the operating unit of each device. The control unit comprises a unit 12 and a control logic input unit 13 for inputting logic data representing control logic relating to the operation of the operation unit of each device. In the model input unit 10, a typical device model and a device element model constituting the device model are registered in a library in advance, and the device model created in accordance with the machine specification data and the shape and dimensions of the device element model are stored in the library. It is registered.

The device model input section 11 executes a device model input routine illustrated in FIG. In the model input routine, the model input unit 11 displays a message prompting selection of a device type together with a library of device models and device element models on a screen of an image device of a computer, for example, a CRT. In response to this selection request, the operator refers to the mechanical specifications, drawings, and the mechanical specifications that are created based on the specifications and described in a tree hierarchy format, and from the library displayed on the screen, transports the simulation target. A required one of the devices constituting the system (here, the transport mechanism of the boxing machine) is selected by a mouse operation or the like (step S1). If the device model to be selected is not registered in the library, a new device model is generated by combining the device element models of the library, and the new device model is registered in the library, and the device type is set as the device type. select.

When the device type is selected in this manner, the model input unit 11 generates a message requesting the input of the shape and dimensions of the device based on the device model data registered in the library and for each setting item. And a 3D image generated from the device model data registered in the library. If the shape and dimension data has already been input, a table or 3D image describing the existing data is displayed on the screen together with a message asking whether data editing is necessary. The above-mentioned shape / dimension data input request is sequentially issued for all of the device elements constituting the selected device.

When the operator completes the input or edit of the shape and dimension data for the device and the device elements by operating the keyboard and mouse in response to the input and edit request for the shape and size (step S2), the model input unit A message requesting entry of the basic specifications of the selected device is displayed on a screen together with a table for inputting specifications. This specification input request is sequentially issued for all of the device elements constituting the selected device. Here, the basic specifications are mainly set with respect to the movable portion of the device, and include the stroke length,
Includes setting items such as speed, operation time, and initial position. If there is input basic specification data, a message asking whether data editing is necessary and a specification editing table describing existing data are displayed on the screen.

Next, when the input operation or the editing operation of the basic specifications (Step S3) is completed, the model input section 11 displays a 3D model of the apparatus on the screen as shown in FIG. It is displayed (step S4).
In the 3D model, an apparatus, an actuator, a tool, a sensor, a work, and the like in the apparatus are represented. In this way, the model shape is displayed on the model viewer (screen) in a three-dimensionally editable manner. By performing a mouse operation as needed, the operator can directly specify the device element model and correct the attributes, and can correct the parent-child relationship between the device objects.

Next, the model input unit 11 displays on the screen a message asking whether data input has been completed for all devices of the transport system (step S5). And
When the operator selects the option “input not completed” in response to this message by operating the mouse, the input model unit 11
Returns to step S1, displays a message requesting selection of the device type, and repeats the data input process from step S1. On the other hand, when the option “input completed” is selected in response to the message asking for the input completion, the model input routine of FIG. 3 ends.

As described above, in the present embodiment, an object expression is used to realize the device and the device element on software, and the shape dimensions and basic specifications are set for each device object as necessary. It is possible to define a parent-child hierarchical relationship between device objects.
That is, a device may be represented as a parent object that has one or more other devices and objects such as actuators, tools, sensors, etc. as children. In other words, each device element model can be reused for another device or the like by copying, modifying, etc., and redefining the parent-child relationship.

Next, the behavior input unit 12 of the data input unit 10
Will be described. The behavior input unit 12 executes a behavior input routine shown in FIG. 5 in order to input the behavior of the device element, in particular, the behavior of the movable unit of the device, and the conditions for disappearance / takeover of the work.
In this behavior input routine, the behavior input unit outputs a message requesting the setting of the position at which the work is generated in the transport system structure data (device object hierarchy) in which all the device types selected in the model input routine are described in a tree hierarchy format. List) is displayed on the screen. In response to this request, when the device related to the work generation is selected by mouse operation, the behavior input unit 12 displays the details of the corresponding part of the hierarchical list or the corresponding device model among the models created by the model input routine on the screen. Display and wait for operator's mouse operation. And the operator can use hierarchical list or 3D
When the cursor is moved to a desired position on the model and a mouse click operation is performed, the behavior input unit determines the work occurrence position and stores it in the memory. The same applies to the work disappearance position (step S11).

When the setting of the work occurrence and disappearance positions is completed, the behavior input unit 12 displays a message requesting the setting of the work occurrence frequency on a screen together with a setting column, and the operator indicates the work occurrence frequency via the keyboard. When a numerical value is entered in the setting field, the work occurrence frequency is stored in the memory (step S12). Next, the behavior input unit 12
Displays on the screen a message requesting the selection of a device together with the hierarchical list, and then, in response to this request, when the operator selects a device from the device list by operating the mouse (step S13), the device on the upstream side (work) On the screen requesting the setting of the takeover source). When the upstream device is selected by a mouse operation, the upstream device is stored in the memory as the work takeover source device, and then a message requesting the setting of the downstream device (work takeover destination) is transmitted. Display on the screen. When the downstream device is selected, the behavior input unit 12 stores this downstream device as a work takeover destination device (step S14). The takeover source / takeover destination of the work is used as auxiliary information during the execution of the simulation for the purpose of specifying the device to which the work belongs, and thereby, for example, the work that has been operated in a free state (described later) can be transferred to the next device or tool. Can be taken over reliably.

Next, the behavior input unit 12 selects, for each device type, behavior data for a device that has been selected as a behavior setting target from a behavior data group created based on, for example, operation specifications of the device. This behavior data is displayed on the screen together with a message asking whether editing is necessary. In the present embodiment, the behavior data is described in the form of a behavior command sequence, and the behavior command is represented in a function format having arguments such as an operation direction, an operation trajectory, an operation distance, and an operation time of the movable unit of the selected device. . In some cases, the basic device specifications already input in the model input routine are set as arguments of the behavior command. Further, in the work behavior process described later, a behavior definition of a work in a free state may be used, and this work behavior definition is included in the behavior data. The work behavior definition relating to the free state can be described, for example, in a function format using the operation direction, the operation trajectory, the operation distance, the operation time, and the like of the work as arguments, and can be defined by the user as necessary.

If editing of the behavior data is unnecessary, the operator clicks the mouse with the cursor positioned on the option "edit not required". On the other hand, if the operator edits the behavior data, the option "edit required" is designated with the mouse. Modify the argument of the behavior command after selecting by operation. As described above, when the input of the behavior data for the device selected as the behavior input target is completed (step S15), the behavior input unit 12 determines that the input of the behavior data for all of the machines, that is, the devices constituting the transport system has been completed. It is determined whether or not the process has been completed (step S16). If the determination result is negative, a message requesting selection of a behavior setting target device is displayed on the screen. On the other hand, when it is determined that the input of the behavior data has been completed for all the devices, the behavior input routine ends. Although the description is partially omitted, the behavior data can be edited in the same manner as in the case of editing the model data.

Hereinafter, the control logic input section 13 of the data input section 10 will be described. The control logic data used for the simulation together with the model data and the behavior data is input to the control logic input unit 13 by an input operation by an operator based on the control specification. A feature is that logic can be described in a natural language (for example, Japanese) format.

The following table shows a part of the control specification.

[0039]

[Table 1]

In the present embodiment, the control logic is defined as a combination of a logic part formed by connecting logical elements by logical conditions and an execution operation, and the logic element is defined as a combination of a sensor item and its state. Is done. The control logic input unit 13 implements a control logic input routine shown in FIG.

In this routine, the control logic input unit 13 displays a message requesting the setting of the sensor item and its state on the screen together with the 3D model, the object hierarchy list, the sensor list, and the options “ON” and “OFF”. In response to this setting request, the operator selects a sensor item (for example, arrival at a carton) from a sensor list by mouse operation while referring to the control specification,
Next, when the user clicks on an option “ON” or “OFF” relating to the sensor state (for example, ON or OFF), the sensor item and its state are stored in the memory of the control logic input unit (step S21).

Next, the control logic input unit 13 displays two options "and" and "or" on the screen together with a message requesting the setting of the logical condition, and when the operator clicks on one of the options, the logical condition is set. It is stored (step S22). Next, the control logic input unit 13 outputs a message asking whether the setting of the logic elements constituting the logic unit has been completed and two options “setting completed” and “setting not completed”.
Is displayed on the screen (step S23). When the option “setting not completed” is clicked, a request for setting a new logical element is requested, while when the option “setting completed” is clicked,
A message requesting the setting of the execution operation is displayed on the screen together with the 3D model, the object hierarchy list, the operation name list, and the setting column.

In the present embodiment, the execution operation is expressed as a combination of the device / tool to be started and the execution operation name. In response to the execution operation setting request, the operator refers to the control specification. In addition, a tool to be started (for example, a carton cut cylinder) and an operation name are sequentially designated by a mouse operation from an object hierarchy list or an operation name list. When the execution operation is input in this manner, the control logic input unit stores the execution operation in association with the already input logic unit (step S24), and then stores the execution operation from when the logic unit is established to when the operation is executed. A message asking whether the delay time needs to be set and a delay time setting field have two options "necessary",
Displayed together with "unnecessary". When the operator sets the delay time or clicks the option “unnecessary” (step S25), the control logic input unit 13 determines whether or not the control logic input for all the devices to be set with the control logic in the machine is completed. 2 with a message to ask
The two options "input completed" and "input not completed" are displayed on the screen (step S26), and if the option "input not completed" is clicked, the process returns to step S21 to return to the logic section related to the new control logic input. While a message requesting an input is displayed on the screen, when the option “input completed” is clicked, the control logic input routine ends. Although the description is omitted, the control logic data can be edited similarly to the case of the model data.

As described above, the simulator of this embodiment contributes to the exchange of information between engineers by enabling the control logic to be described in a natural language. A part of the control logic used for controlling the apparatus shown in FIG. 4 is exemplified below. [Example of control logic description] (Carton cutout logic) ・ Carton reach sensor ON and 5 push-in cylinder retracting end sensor ON and carton cutting cylinder backward end sensor ON if ON Carton cutting cylinder forward ・ Carton cutting cylinder forward end sensor ON Carton cut cylinder retreat (5 cartons pushing logic) ・ Carton number counting forward end sensor ON and 5
If the reaching sensor is ON, 5 push cylinders advance. ・ 5 push cylinder advance end sensors ON and the carton cut-out cylinder retreat end sensor. If ON, 5 push cylinders retract (positioner one step down). ・ 5 push cylinder forward end sensors ON. And if the carton floating sensor is ON, the positioner goes down one step (Positioner load station) ・ If the push-in sensor of the 5-push cylinder is ON and the positioner lowering count sensor is ON, go to the load station As described above, the simulator is the data input unit 10
And a data storage memory 20 for storing the data input to the memory. When data is stored in the data storage memory from the data input unit, the data input unit 10 can convert the data format into a format suitable for internal processing in the simulator. The data storage memory 20 includes a device model input unit 11, a behavior input unit 12, and a control logic input unit 1.
3 has a device model storage memory 21, a behavior storage memory 22, and a control logic storage memory 23 for respectively storing the data input to the device 3.

Hereinafter, an outline of the simulation processing by the simulation execution unit 50 will be described. In the simulation execution routine shown in FIG. 7, the simulation execution unit 50 resets the simulation clock and the shared memory in the initialization processing of step S31, and then executes the simulation control condition storage memory 40.
Device model data to be simulated according to the control conditions read from the
And a three-dimensional model is constructed based on the device model data. Then, the behavior data and control logic data of the operable model part (device movable portion) are read from the behavior storage memory 22 and the control logic storage memory 23. Loading and linking the input and output of the control logic to the behavior data. When the standby state before the start of the simulation is thus established (step S3)
2), the simulation execution unit 50 displays a message asking whether or not to start the simulation, together with the option “start” (step S33).

The above-described step S32 constitutes a model generation unit in the simulator together with the device model generation processing in step S34 described later. Then, when the option “start” is clicked by the operator, the simulation execution unit 50 executes the control simulation based on the simulation clock in the unit time progress method and for the designated period (step S34,
S35).

In this simulation, a model of the device to be simulated is generated, and a model of the work is generated at the position where the work is generated, and the behavior processing of the tool and the behavior processing of the work accompanying the tool are performed. In addition, input processing to the control logic is performed according to sensor detection during the execution of the simulation, and behavior processing is performed according to an operation output from the control logic. In this way, the simulation is executed while the control logic process and the behavior process interact with each other via the shared memory.

The simulation performed by the simulation executing unit 50 is generally performed as described above. When the simulation is performed, in the present embodiment, the mutual interaction between the device objects of the transport system (for example, the transport mechanism) to be simulated is performed. With or without action, especially
Determines the working state of the work (including the passive movement of the work) based on the presence / absence of interaction between the sensor, tool, and work, and a predetermined discriminant rule. It is characterized by being implemented at the level.

More specifically, in this embodiment, the working state of the work is divided into four states: a free state, a restricted state, a fixed state, and an interference state.
It is divided into two. Here, the “free state” refers to an operation state in which the work is not restricted by a tool or the like. For example, when a workpiece falls from the device,
When the workpiece performs an inertial operation after being driven by the pusher on the plate, the workpiece is defined as being in a free state.

When the work is in a free state, behavior processing is performed according to the behavior definition of the work itself set in the behavior input processing of FIG. That is, the behavior of the work in the free state can be defined independently of the tool behavior. In this connection, when the operation of the device object is complicated and it is difficult to define the behavior of the device object, the simulation is simplified by defining the behavior of the work itself assuming that the work is in a free state. be able to.

Next, the "constrained state" refers to an operation state in which the work is operating in accordance with the operation of the tool for driving the work, but is subjected to stronger restrictions from another apparatus object. In this case, the work operates according to the device object that exerts the constraint.
For example, a work placed on a belt conveyor moves in accordance with the movement of the belt, but stops while slipping when it hits a stopper. The “constrained state” is used for expressing such a work operation. The restrictions on the work are
The work is released when the work is transferred from the belt conveyor device to another device. However, when the work is belt-driven by the transferred device, a new restriction may be imposed.

Next, the "fixed state" refers to a work state in which the work is driven by a tool or another work. In the fixed state, the work is preferentially driven by the tool that drives the work, even if there are restrictions of other tools, and the operation of the work follows the operation of the preferential tool. For example, when a workpiece on a belt conveyor is pressed by a pusher, the workpiece is fixed with respect to a pusher (a tool prior to the conveyor) in order to consider the action of the pusher in preference to the action of the conveyor. Express. The fixed state of the work is released when the tool for driving the work stops operating or when interference occurs between the work and another tool or another work.

Next, the "interference state" is defined between a work and an apparatus or a work. When the apparatus objects physically contact or overlap each other, the detected partner object is detected. Is inoperable and this object has to be stopped. Therefore, when the opponent object is operable and accompanies with the object of ours, no interference state is formed. Note that even if interference is detected, no output is made to the control logic.

For example, when a work collides with a stopper which is a device element while traveling on a conveyor, interference between the work and the stopper is detected, and the work operation is stopped. At this time, the conveyor belt does not stop operating. On the other hand, when the workpiece is driven by the pusher and hits the stopper, not only its own stopping operation but also the pusher performs the stopping operation. As can be seen from the above example in which the workpiece interferes with the stopper, if interference occurs between the workpiece and device elements other than the tool while the workpiece is being driven by the tool, depending on the type of tool, the operation of the tool may also be affected. May be affected.

As described above, in the above-described simulation execution routine (FIG. 7), based on the presence / absence of interaction between the device objects and a predetermined discriminant rule, the work is set in the free state, the restricted state, the fixed state, or the interference state. It is determined which of the states is in the operating state. The presence / absence of interaction (physical contact) between the device objects is determined by the simulation execution unit 50 from the position information of each of the work and one or more device elements of the device to which the work belongs.

As will be described later in detail, as shown in step S44 of the tool behavior processing routine of FIG. 8 and step S61 of the work behavior processing routine of FIG.
The presence or absence of the interaction between the device objects is determined from both the tool side and the work side. Then, the processing routine of FIGS.
Are apparently performed simultaneously with each other. The discriminant rules for discriminating the working state of the work include the flowchart of the subroutine for determining the working state of the work in FIG.
6 and S48.

As described above, the discrimination rule of the work operation state is shown in FIG.
10 is evident from the flowchart of FIG. [Discriminant Rule 1] If the work interacts with the device object on the downstream side in the work operation direction and this device object is not another work, it is determined that the work is in an interference state (steps S71, S72 and S74 in FIG. 10). Corresponding to).

[Determination Rule 2] If the work is operable and interacts with the device object on the upstream side in the work operation direction, it is determined that the work is in the fixed state (steps S71, S79 and S80 in FIG. 10). Corresponding to). [Determination Rule 3] If the tool interacts with the work and the work is not in the fixed state, it is determined that the work is in the restricted state (corresponding to steps S44, S45 and S48 in FIG. 8).

[Determination Rule 4] If the work is not in the fixed state, the interference state or the constraint state, it is determined that the work is in the free state. In the present embodiment, when the sensor detects that the device or the work has reached a predetermined position, the sensor outputs the “sense” output to the control logic in relation to the determination of the interaction between the device objects. To be sent to For example, when a workpiece approaches a sensor provided at a predetermined sensing position, the sensor searches for an object within a certain distance range at an arbitrary cycle, and when a specified object is searched, Find the distance between the sensor and the nearest point. Then, when the work is closer to the sensing frequency change position, the sensing cycle is shortened, and when the work reaches the sensing position or a position within the sensing position, a detection signal is output to the control logic.

In the present simulation, the interaction target can be limited in advance, thereby reducing the calculation amount for detecting the interference-related device object. The position information to be detected may be only the traveling direction (one axis). Hereinafter, a tool behavior processing subroutine executed in the simulation execution routine will be described.
This subroutine constitutes a device element behavior processing unit for determining the behavior of a device element, particularly a tool, in the simulator.

In the tool behavior processing subroutine shown in FIG. 8, when receiving the operation command from the control logic (step S41), the simulation execution unit 50 determines whether the operation command is a stop command (step S4).
2). When determining that the operation command is not the stop command, the simulation executing unit operates the tool according to the tool operation registered in advance in the behavior input unit 12 (step S43). That is, a simulation of the tool operation is performed.

During the operation of the tool, the simulation executing section 50 determines whether or not the workpiece has been detected by determining whether or not the tool has contacted the workpiece (step S4).
4) If a work is detected, it is further determined whether or not the work is in a fixed state with reference to the determination result in the work operation state determination routine of FIG. 10 (step S4).
5). In this determination, if it is determined that the work is in a fixed state, that is, the work is to be fixed to the tool, the work is fixed to the tool (step S4).
6) The tool operation is continued with the work accompanying the tool (step S47). On the other hand, when it is determined that the work is not in the fixed state, the simulation execution unit restricts the work to the tool (step S48), and causes the work to operate on the tool (step S49).

During the operation of the tool, the simulation execution unit 5
0 determines whether or not interference has occurred between the tool or the work fixed or restricted by the tool and another device element or another work (step S50). Stop the operation (step S5
2) Then, the fixed state of the work by the tool is released (step S53), and the tool behavior processing subroutine is terminated.

On the other hand, if it is determined that no interference has occurred, it is determined whether or not a stop command has been received from the control logic (step S51). If this determination result is negative, the flow returns to step S43 to return to the tool. Continue operation. When it is determined in step S51 that the stop command has been received, the tool operation is stopped and the fixed state of the work is released (steps S52 and S53), and the present subroutine ends.

The work behavior processing / action state determination subroutine executed in the simulation execution routine will be described below. This subroutine constitutes a work behavior processing unit in the simulator. In the work behavior processing subroutine shown in FIG. 9, the simulation execution unit 50 determines whether or not there is contact between the work and other device objects (device elements, tools, and work) to detect the device object from the work side. It is constantly monitored whether or not it has been performed (step S61).

If no device object is detected, the simulation executing section 50 determines the work operation state with reference to the result of the work operation state determination routine shown in FIG. 10 (step S62), and according to the work operation state. The work is operated, thereby simulating the work behavior. At the time of creating a work, the program flow does not pass through the determination routine of FIG. 10, and the working state of the work is set to a free state at the time of creating the work.

More specifically, if the work is in a free state, the work is operated according to the behavior definition of the work itself (step S63). This work operation continues unless a device object is detected. If the work is in the restricted state, the work is operated according to the tool operation of the device where the work is currently located (step S6).
4) It is determined whether or not the work has been transferred to another device (step S65). If there is no transfer and no device object is detected, the work operation according to the tool operation is continued. On the other hand, if there is a transfer to another device,
The simulation executing unit releases the work from the restriction imposed by the device before the transfer, and then operates the work under the restriction from the device to which the transfer has been made (step S66). This work operation continues unless a device object is detected.

If it is determined that the work is fixed by the tool or another work, the simulation executing section 50 operates the work according to the operation of the tool or another work (step S67). This work operation continues if no device object is detected. FIG.
In the work behavior processing subroutine, when the work comes into contact with another device object, that is, when the device object is detected, the simulation execution unit 50
Executes a work operation state determination subroutine (step S68) shown in detail in FIG.

In this subroutine, the simulation executing section 50 determines whether the device object detected in the work behavior processing subroutine is on the downstream side or the upstream side in the work operation direction (step S71). If the device object is on the downstream side of the work, it is determined whether or not this device object is another work (step S72), and if it is another work, it is further determined whether or not it is operable. (Step S73).

If the device object on the downstream side of the work is a device object other than another work, step S72.
If it is determined in step S73 that the workpiece is another work that cannot be operated, the simulation execution unit 50
Stores that the work is interfering with such a device object (step S74), and then stops the operation of the work (step S75).

On the other hand, if it is determined in step S73 that the device object on the downstream side of the work is another operable work (partner work), the simulation execution unit 50
Determines further whether or not the work is stopped (step S76). If the work is not stopped, the simulation execution unit fixes the other work to the work (step S77), whereby the other work is driven along with the work. Thereafter, when the work stops, the fixing of the partner work to the work is released (step S78).

If it is determined in step S71 of the work operation state determination subroutine that the device object detected in the work behavior processing subroutine is on the upstream side of the work, the simulation execution section 50 determines whether the work is operable. It is determined (step S79), and if the work is operable, the work is fixed to the upstream device object (step S80). In this case, the work is driven together with the upstream device object. On the other hand, if the work is inoperable, the simulation executing unit stores that the inoperable work is interfering with the upstream apparatus object (step S81). In this case, the work operation is stopped.

As described above, in the work operation state determination subroutine, the operation state of the work interacting with the device object is determined according to the determination rules shown in the flowchart of FIG. 10 and the block diagram of FIG. After determining the work operation state in this way, the simulation execution unit 50 executes the work behavior processing subroutine of FIG. 9 again to simulate the work behavior.

In the simulation execution routine of FIG. 7, tool behavior processing (FIG. 8) and work behavior processing (FIG. 9)
And FIG. 10) are implemented cooperatively and apparently simultaneously, as is clear from the above description,
Hereinafter, with reference to FIG. 11, the behavior processing of the tool and the work, particularly, the determination of the work operation state will be further described from a different viewpoint from FIGS. 8 to 10.

In the behavior process shown in FIG. 11, the simulation execution unit 50 is built in the
Referring to a work table 51 and a device / tool function table (device / sensor function table) 52, a part of which is exemplified in FIG. 4, behavior processing of each tool and work is performed. That is,
The simulation execution unit 50 reads the position information of the work from the work table 51 to determine the device to which the work belongs (hereinafter, referred to as belonging device), and further refers to the device / tool function table 52 to determine the tool of the belonging device. Discriminate, and for each tool, the tool name, location information,
The action and direction of the tool on the workpiece are sequentially determined. next,
Based on the operation and direction of each tool, the operation and direction to which the work is applied from each tool is determined, and further the work traveling direction is determined. On the other hand, the current position information of each tool is obtained from the action / direction and arrangement information of each tool, and the operation state of the work is determined from the tool position information and the result of comparison between the work traveling direction and the tool operation direction, Furthermore,
The operation state and direction of each tool are determined. Then, a priority tool that acts on the workpiece in preference to another tool is determined based on the workpiece operation state and the operation state / direction of each tool, and the operation of the workpiece by the priority tool is determined.

FIG. 12 is a two-dimensional schematic diagram of the device shown three-dimensionally in FIG. 4 and 12, the carton (work) 10 conveyed to the stopper 102 by the conveyor belt 101, as can be seen from the above description example of the control logic and the control specifications shown in Table 1.
3 is sequentially cut out by a carton cut-out pusher 104, five pieces are stacked on a stacking plate 105, and the elevator 108 is lowered by one step each time five push-in pushers 106 push five cartons into the stacking portion 107. Has become. 4, reference numerals 111 and 11
Reference numeral 2 denotes a tool forward end sensor and a tool backward end sensor, and 113 denotes a work detection end sensor.

By applying the above-described work and tool behavior processing to such an apparatus, a change in the work operation state with the progress of the work operation is obtained as shown in FIG. FIG. 15 shows a state in which the first work (work 1) 103a has been conveyed onto the accumulation plate 105, and the second work (work 2) 103b is generated on the upstream side of the conveyor. The process until it is integrated on the top is shown. The work transfer path is expressed as follows in a device (or device element) / tool format.

Conveyor / Belt → Conveyor / Stopper → Conveyor / Pusher → Collecting Plate / (No Tool) FIG. 15 shows operation steps (1) to (10) (main events occurring in the process from generation of work 2 to accumulation). 2) shows the working state of the work and the associated devices. FIG.
As can be seen from the above, according to the simulator of the present embodiment that performs the tool / work behavior processing described above, it is possible to simulate the two-dimensional operation of the transfer device as shown in FIG. That is, according to this simulator, the behavior of a plurality of workpieces can be simulated for a workpiece whose operation direction is one axis. In addition, as shown in FIG.
The work behavior state is simulated by extending the work action state determination processing to three dimensions.

As described above, in the simulation according to the present embodiment, the three-dimensional transport of the transport system is performed using the upstream and downstream devices (work takeover source and takeover destination) of each device set in the simulator as reference information. Determines on which device the work to be transported along the route is located, and determines the work state of the work based on the presence or absence of interaction between the work and each device element or another work and the discrimination rule. It is to be determined. For this reason, the working state of the work and its change while being conveyed in the apparatus and between the apparatuses are constantly grasped, and the behavior of the work can be expressed well. That is, the simulator according to the present embodiment simulates the tool behavior and the workpiece behavior at the actual machine level based on the above-described simulation principle unique to the present invention, paying attention to the fact that the work operation state and its change affect the simulation accuracy. It has become something.

The present invention is not limited to the above embodiment, but can be variously modified. For example, in the embodiment, a case has been described in which the simulator and the simulation method performed by the simulator are applied to a transport mechanism of a box packing machine. However, the present invention can be applied to simulation of operations of various transport systems. Further, in the embodiment, the case where the work operation state is divided into the free state, the fixed state, the constraint state, and the interference state has been described, but it is not essential that the work operation state is divided in this way. Further, in the embodiment, a device model including a sensor in addition to a work and a device is generated, and a sensor output is generated in accordance with an interaction between the work and the sensor. The simulator and the simulation method of the present invention are not limited to this, and the simulation may be performed in cooperation with the actual machine PLC.

[0081]

The simulation method according to the present invention is applied to a transfer system including a plurality of devices constituting a work transfer mechanism. In the simulation method, a model representing a device to which a work belongs is generated based on the mechanical specifications of the transfer system. Based on the operation specifications and control logic of the transport system, determine the behavior of the device element of the device to which the work belongs, and determine whether or not there is an interaction between the work and each device element or another work and a predetermined determination rule. Based on the behavior of the work based on the behavior of the device elements and the work state of the device, the work behavior of the model is simulated together with the behavior of the device elements. Can be simulated at the level of detail equivalent to the actual machine, and the design specifications of various transport systems, especially control It can be optimized within a short period of time the like.

Further, in the simulation method of the present invention, if a model including a sensor is generated and a sensor output is generated for the sensor logic when an interaction occurs between the workpiece and the sensor, a real machine The simulation can be performed only by a system independent of
The design specifications, especially the control specifications, of the transport system can be described in a natural language, and communication between engineers during the design process can be performed smoothly.

Further, the simulator according to the present invention includes model data representing the shape and dimensions of each device of the transport system to be simulated, behavior data representing the behavior of device elements of each device, and logic data representing control logic for each device. A data input unit for inputting simulation data including: a data storage unit for storing simulation data for each device; a simulation control input unit for selecting simulation data for the device to which the work belongs; and a simulation execution unit for performing simulation. A simulation result confirmation unit that records the result of the simulation executed by the simulator execution unit. The simulation execution unit assigns the work based on the model data selected by the simulation control input unit. A model generation unit that generates a model representing a device to be operated, a device element behavior processing unit that determines the behavior of a device element of the device to which the work belongs based on the behavior data and the logic data selected by the simulation control input unit, The operation state of the work is determined based on the presence or absence of interaction between the device element or another work and a predetermined discriminant rule, and the behavior of the work is further determined based on the operation state of the work and the behavior of the device element. And simulates the behavior of the workpiece and the device element in the model, so that the behavior of the workpiece and the device element (especially the device movable unit) in the transport system can be simulated with a level of detail equivalent to the actual machine. Also, based on simulation results displayed in the form of, for example, three-dimensional images or character information, The optimal design specifications of the system will be able to determine within a short period of time.

[Brief description of the drawings]

FIG. 1 is a schematic block diagram of a simulator according to an embodiment of the present invention.

FIG. 2 is a diagram showing a part of a tree-like hierarchical structure which is a representation form of device elements in the simulator of FIG. 1;

FIG. 3 is a flowchart of a device model input routine executed by the device model input unit shown in FIG. 1;

FIG. 4 is a diagram illustrating a three-dimensional device model displayed on a screen in the device model input routine of FIG. 3;

FIG. 5 is a flowchart of a behavior input routine executed by the behavior input unit shown in FIG.

FIG. 6 is a flowchart of a control logic input routine executed by the control logic input unit shown in FIG. 1;

FIG. 7 is a flowchart of a simulation execution routine executed by the simulation execution unit shown in FIG. 1;

FIG. 8 is a flowchart of a tool behavior processing subroutine executed in the simulation execution routine of FIG. 7;

FIG. 9 is a flowchart of a work behavior processing subroutine executed in a simulation execution routine.

FIG. 10 is a flowchart of a work operation state determination subroutine executed in a simulation execution routine.

FIG. 11 is a diagram illustrating behavior processing of a tool and a work performed by a simulation execution unit.

FIG. 12 is a two-dimensional schematic diagram of the device shown in FIG.

FIG. 13 is a diagram exemplifying a part of a work table used in behavior processing of a tool and a work.

FIG. 14 is a diagram exemplifying a part of a device / tool function table used in processing of behavior of a tool and a work;

FIG. 15 is a diagram showing a change in a working state of the workpiece with the progress of the apparatus operation obtained by applying the behavior processing to the apparatus shown in FIG. 12;

[Explanation of symbols]

 Reference Signs List 10 Data input unit 11 Device model input unit 12 Behavior input unit 13 Control logic input unit 20 Data storage memory 21 Device model storage memory 22 Behavior storage memory 23 Control logic storage memory 30 Simulation control input unit 40 Simulation control input unit 50 Simulation execution unit 51 Work Table 52 Device / Tool Function Table 60 Simulation Result Storage Memory 70 Simulation Result Checking Unit 101 Conveyor Belt 102 Stopper 103, 103a, 103b Carton (Work) 104, 106 Pusher 111, 112, 113 Sensor

Continued on the front page (72) Inventor Koji Kumagai 149 Komagaidai, Nagareyama-shi, Chiba F-term in Tokyo Automatic Machinery Works Co., Ltd. JA04

Claims (7)

[Claims] 1. A method of simulating a transfer system including a plurality of devices constituting a two-dimensional or three-dimensional work transfer path, comprising: generating a model of a device to which a work belongs based on machine specifications of the transfer system; The behavior of the device element of the device to which the work belongs is determined based on the operation specifications and control logic of the transfer system, and the presence or absence of interaction between the work and the device element or another work and a predetermined determination rule are determined. Determining a working state of the work based on the behavior of the device element and the working state of the work based on the behavior of the device element and the behavior of the device element in the model. A method of simulating a transport system including a plurality of devices constituting a transport path. 2. The method according to claim 1, wherein the predetermined discriminating rule defines an action state of the work based on an action and a direction of the device element or another work on the work. 3. The method of simulating a transfer system including a plurality of devices constituting a work transfer path according to claim 1. 3. An operation state of the work, a free state in which no interaction occurs between the work and the device element or the another work, and the work is driven by the device element or the another work. Wherein the work is divided into a fixed state, a restricted state in which the work is restricted by the device element, and an interference state in which the work contacts or overlaps the inoperable device element or the another work. The method of simulating a transfer system including a plurality of devices constituting a work transfer path according to claim 1. 4. The method according to claim 1, further comprising: generating a model including a sensor of a device to which the work belongs, and generating a sensor output in the control logic when the work interacts with the sensor. And a simulation method of a transfer system including a plurality of devices constituting a work transfer path. 5. The method according to claim 1, wherein the control logic is input in a logical expression format using a natural language. 6. A simulator for simulating a transfer system including a plurality of devices constituting a two-dimensional or three-dimensional work transfer path, comprising: model data representing the shape and dimensions of each device; device elements of each device; A data input unit for inputting simulation data including behavior data representing behavior of the device and logic data representing control logic for each of the devices; a data storage unit for storing the simulation data for each of the devices; A simulation control input unit that selects simulation data for the device; a model generation unit that generates a model representing the device to which the work belongs based on the model data selected by the simulation control input unit; and a simulation control input unit. Choice A device element behavior processing unit that determines the behavior of the device element of the device to which the work belongs based on the acquired behavior data and logic data; and whether or not there is any interaction between the work and the device element or another work. Determining a working state of the work based on a determined discriminant rule, further including a work behavior processing unit that determines the behavior of the work based on the working state of the work and the behavior of the device element; A simulation execution unit that simulates the behavior of the workpiece in the model together with the behavior of the device element; and a simulation result confirmation unit that records a result of the simulation executed by the simulator execution unit. Simulator of a packaging line system including a plurality of devices to be configured. 7. The apparatus according to claim 6, wherein the data input unit inputs the logic data in a logical expression format using a natural language. Transport system simulator.