JP2002366206A - Simulating method and device therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prepare a highly reliable timing chart for performing work simulation to work of equipment by a three-dimensional model. SOLUTION: A simulator for generating a pseudo signal in accordance with an output of a sequencer 1 and giving the pseudo signal to the sequencer 1 performs simulation to verify a program operation of the sequencer 1, prepares a timing chart of an input-output operation on the basis of the input-output operation of the sequencer 1 in the simulation and performs work simulation by the three-dimensional model for the equipment work on the basis of the timing chart.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for simulating a work using a three-dimensional model of equipment for working on a work.

[0002]

2. Description of the Related Art Usually, a production facility including a device for moving a work, a robot for processing the work, and the like is controlled by a sequencer (a programmable ladder controller; hereinafter, also appropriately referred to as a PLC). Although the program of the sequencer for controlling the equipment is manually created, when the equipment is operated by the program, it is necessary to verify operation such as interference check of the equipment. Three-dimensional C
It is known to perform a work simulation using a three-dimensional model using an AD system. Conventionally, when performing a work simulation using this three-dimensional model, the operation timings of the actuators and workpieces that constitute the equipment are separately set manually.

Japanese Patent Application Laid-Open No. 9-244724 discloses a method of creating an operation program for a robot, in which an operation program for a robot is created based on a three-dimensional model of a workpiece, and then a three-dimensional model is created based on the operation program. Is described, and the operation program is modified based on the result of the simulation. This publication does not disclose a method of setting the operation timing of an actuator or a work constituting the equipment.

[0004]

As described above, in the conventional method of manually setting the operation timing of the actuators and the workpieces constituting the equipment, the operation is performed between the operation verification using the three-dimensional model and the actual operation of the equipment. The timing may be shifted, and the reliability of the verification is low. In addition, when an abnormality occurs in the equipment such as an actuator failure and its operation is stopped, there is no interference between the actuators or between the actuator and the work, and the restoration after the operation is stopped can be performed smoothly. Verification that can be done etc. 3
If it is attempted to use a dimensional model, it is necessary to set various operation timings for verification thereof, which requires much time and effort.

An object of the present invention is to solve the above-mentioned problems.

[0006]

SUMMARY OF THE INVENTION Accordingly, the present invention performs a program verification of a sequencer by a simulator that generates a pseudo signal in accordance with an output of the sequencer, and utilizes a three-dimensional input / output operation of the sequencer at that time. This problem has been solved by creating a timing chart for operation verification using a model.

First, the invention according to claim 1 is a simulator which generates a pseudo signal related to the operation of the equipment in accordance with the output of the sequencer which controls the equipment, and provides the same to the sequencer by means of a simulator. A timing chart of the input / output operation based on the input / output operation of the sequencer during the simulation, and performing a work simulation using a three-dimensional model for the work of the equipment based on the timing chart. Is a simulation method characterized by the following.

According to a second aspect of the present invention, there is provided a sequencer for controlling equipment, and a pseudo signal related to the operation of the equipment is generated in accordance with an output of the sequencer for simulating equipment operation by a program of the sequencer. A simulator to be provided to the sequencer; a timing chart generating means for generating a timing chart of the input / output operation based on the input / output operation of the sequencer during the simulation; A three-dimensional simulation means for executing a work simulation using a three-dimensional model.

That is, the simulation of the equipment operation by the program of the sequencer is performed by generating a pseudo signal in accordance with a predetermined criterion with respect to the output (various operation commands) of the sequencer and giving the pseudo signal to the sequencer. Through this simulation, it is possible to verify whether the program is finished to the intended contents or whether the program will take appropriate action when there is an abnormality in the equipment, and make corrections to the program as necessary. it can.

The timing of the input / output operation of the sequencer in this simulation corresponds to the operation timing of the equipment.

Therefore, in the present invention, while performing the simulation by the simulator, the input / output operation of the sequencer at that time is recorded, and a timing chart for a work simulation using a three-dimensional model is created. .

Therefore, the obtained timing chart reflects the actual control operation of the equipment by the sequencer. Therefore, 3 based on this timing chart
It is possible to eliminate a timing difference between the operation timing of the equipment and the work at the time of the operation simulation using the dimensional model and the operation timing of the equipment and the work when the equipment is actually operated by the sequencer. Therefore, the reliability of the operation verification such as the interference check between the actuators and the interference check between the actuator and the work using the three-dimensional model becomes high.

[0013] In addition, if the above simulator is used to simulate various types of equipment abnormalities such as abnormal stop of the equipment, manual recovery, and restart of the operation of the equipment, the timing chart for the time of the abnormality can be prepared without separately preparing the timing chart. The operation verification at the time of such equipment abnormality can also be performed by a work simulation using the three-dimensional model.

[0014]

As described above, according to the present invention, a timing chart of an operation for verifying the operation of a facility by a three-dimensional model using a simulation result by a simulator that generates a pseudo signal in accordance with an output of a sequencer. It is not necessary to manually create a timing chart for equipment operation verification using a three-dimensional model, and the operation verification is based on the actual equipment movement. The time and effort required for this can be greatly reduced, and the reliability of the verification can be increased.

[0015]

Embodiments of the present invention will be described below with reference to the drawings.

<Overall Configuration> In FIG. 1, reference numeral 1 denotes an equipment-side PLC (sequencer) for controlling equipment, and 2 denotes a simulation device. The simulation device 2 uses the equipment side P
Simulator side P connected to LC1 by communication line 3
LC4, a computer 5 having input means for performing settings for simulation on the simulator-side PLC 4, a switch operation panel 6 for supplying signals to the simulator-side PLC 4 for performing abnormality setting and recovery, and a three-dimensional CAD system 10 And are connected to each other by the communication line 3.

<Configuration of Simulator-side PLC> The simulator-side PLC 4 is, as shown in FIG.
State calculating means 7 for simulating a change in the state of the equipment based on the operation command from the controller and calculating the change state of the equipment at predetermined time intervals; and based on the change state of the equipment calculated by the state calculation means 7. Simulates whether or not there is an output change in a detector that detects a change in the state of the equipment, and checks the PLC on the equipment side.
1 includes a pseudo signal generating means 8 for generating a pseudo signal related to the state to be output to the device 1 and an abnormality setting program 9.

Further, the simulator-side PLC 4 includes an input-side address conversion program 11 for converting an address of an operation command given from the facility-side PLC 1 into an address for the simulator-side PLC 4, and a simulator-side PLC 4.
And an output-side address conversion program 12 for converting the address of the pseudo signal generated in step (1) into the address for the equipment-side PLC 1 so that the input and output addresses of the equipment-side PLC 1 and the simulator-side PLC 4 are unified.

Further, the simulator-side PLC 4 uses the three-dimensional CAD system 10 to perform three-dimensional
A timing chart creation program 18 and a memory 19 for executing a work simulation using a dimensional model are provided.

The state calculating means 7 is operated by an operation setting program (operation setting means) 13 for setting operation models of various actuators constituting the equipment and a work to be worked by these actuators, and an operation command of the equipment-side PLC 1. Change position of each actuator (operation state)
Actuator position calculating means 1 for calculating the value at predetermined time intervals
4 and a work position calculating means 15 for calculating a change position of the work at predetermined time intervals.

The operation setting program 13 is provided on the equipment side PLC.
This is for modeling the movement of each of the actuators and the work that are operated based on the operation command from 1 as a coordinate change, for example, a coordinate change on a number line.

Regarding the actuator, the equipment-side PLC
There are various actuators, such as a cylinder in which the piston rod moves from the retreat end to the forward end with an instantaneous output of the operation command from 1, a lifting motor that does not continue to operate unless an operation command is continuously output from the equipment side PLC1. From
Set according to its function or personality. For example, if the rod device moves forward while the forward command is output, and moves backward when the output drops, the operation pattern is symbolized and set, and the forward condition, the backward condition, and the operating range ( The time required to operate from the forward end to the backward end) and other necessary conditions are set.

As for the work, for example, if the work moves from the conveyor A having the work stopper to the conveyor B and moves by the conveyor B, the work is present on the conveyor A, and the work stopper is turned off. And when the conveyor B satisfies the three conditions of performing the forward movement, the work is transferred from the conveyor A to the conveyor B and starts moving on the conveyor B.
When the forward command of the conveyor B is output, the workpiece moves forward, when the reverse command is output, the workpiece moves backward, and when both commands are not output, the workpiece is stopped.
Thus, setting of such an operation pattern, setting of conditions, setting of an operation range (time required for the conveyor B to send a workpiece from one end to the other), and the like are performed.

The actuator position calculation means 14 calculates the operation position of each actuator at predetermined time intervals based on the operation model of each actuator set by the operation setting program 13 and writes the calculated operation position to the memory. That is, since the movement of the actuator is modeled as a coordinate change as described above, the equipment-side PLC
The change in coordinates is calculated every predetermined time (for example, every 0.1 seconds) in response to the operation command from 1.

Similarly, the work position calculating means 15 changes the coordinates of the work at predetermined time intervals (for example, 0.
(Every second) and write it to memory.

The pseudo signal generating means 8 includes a detector setting program 16 for setting detection conditions of a detector for detecting the operation positions of the actuator and the workpiece for sequence control, and the actuator setting program provided by the state calculating means 7. And a pseudo signal generation program 17 for generating the pseudo signal based on the information on each of the workpieces and the detection conditions set in the detector setting program 16.
And

The detector setting program 16 will be described. As for the actuator detector for detecting the operating end of the actuator (for example, the forward end or the backward end of the piston rod of the cylinder), the detection range is determined based on the operating range of the actuator. Set. For example, if the operating range of the cylinder is 100, 1-5, 95-100
Are set as the detection ranges of the forward end and the backward end for outputting the pseudo signal, respectively.

With respect to a work detector for detecting whether or not a work exists at a predetermined position, a condition that the work moving actuator (such as a conveyor) is at a predetermined operation position and a condition that the work exists at the predetermined operation position. Related conditions necessary to assume, that is, the actuator,
Set conditions for operation / detection of other actuators or workpieces. For example, if the detector detects that the workpiece has moved forward to a predetermined position (operating position 50 of the conveyor) by the conveyor in the operating range 100, the operating position 50 of the conveyor, the presence of an advance command for the conveyor, and the like are determined. Set as detection conditions.

The pseudo signal generation program 17 is based on the information on the positions of the actuator and the work and the operation command of the equipment-side PLC 1 given from the state calculation means 7 and the position and the operation command are stored in the detector setting program 16. When the detection condition of the detector set in is satisfied, a pseudo signal (output of the detector) is generated.

The abnormality setting program 9 operates in accordance with an input from the switch operation panel 6, and is operated on the equipment side P.
A command to cancel the operation command from the LC 1 is given to the input-side address conversion program 11, thereby causing a necessary pseudo signal not to be generated, causing an abnormality, and generating a pseudo signal generated by the pseudo signal generation program 17. An abnormality is generated by giving a command to cancel to the output side address conversion program.

Further, the abnormality setting program 9 is provided on the equipment side P
When the operation of the LC 1 is stopped halfway, the calculation programs 1 based on the recovery signal from the switch operation panel 6
An operation command is sent to the state calculating means 7 via the input-side address conversion program 11 so that the position (calculated value) of the actuator or the work at the time of the stop calculated by the steps 4 and 15 is the predetermined position before the stop. give.

In the above example, the switch operation panel 6 is provided separately from the computer 5 for setting and restoring the abnormality. Is also good.

Timing chart creation program 18
Captures various operation command signals via the input-side address translation program 11 during the simulation by the simulator-side PLC 4, captures pseudo signals via the output-side address translation program 12, and performs equipment based on the signals. A timing chart (see FIG. 3) of the input / output operation of the side PLC 1 is generated. The memory 19 stores the timing chart generated by the timing chart creation program 18.

<Configuration of 3D CAD System> 3D C
The AD system 10 includes a CPU (central processing unit), a memory, and the like, and includes a computer, a display, and external input devices such as a keyboard and a mouse.

The computer of the three-dimensional CAD system 10 develops a virtual three-dimensional space on a memory, and stores a three-dimensional model of the equipment (an equipment model other than an actuator such as an actuator model, a work model, a partition) in a virtual three-dimensional space. (See FIG. 4), operate them according to the timing chart generated by the timing chart generation program 18, and display these three-dimensional models on a display. FIG. 4 shows an example of equipment for picking up the window 34 from the rack 33 by the robot 32 and assembling the window 34 to the body 31 of the automobile.

The computer of the three-dimensional CAD system 10 is generated by an interference check unit that monitors the distance between various three-dimensional models to check for data interference and a timing chart generation program 18 of the simulator-side PLC 4. A timing chart processing unit for converting a file (data) format of the timing chart into a file format for a three-dimensional CAD system.

<Simulation of equipment operation by program of equipment-side PLC 1> Simulator-side PLC 4
The simulation of the equipment operation by the program of the equipment-side PLC 1 using the above will be described with reference to the flow shown in FIG.

That is, the simulation is started by setting the signal output, and it is verified whether or not the control program of the equipment-side PLC 1 is abnormal during the normal operation of the equipment (steps A1 to A3). The signal output settings in this case are the setting of the operation model of each of the actuator and the work by the operation setting program 13, the setting of the detector by the detector setting program 16, and the setting of various equipment abnormalities by the abnormality setting program 9.

If the control is stopped due to a program abnormality in the following step A4, the process proceeds to step A5, where the program is corrected and restored. In this case, since the positions of the actuator and the work are calculated at predetermined time intervals by the position calculating means 14 and 15, the state of the actuator and the work when the equipment stops due to a program abnormality can be known. For this reason, it is easy to determine the cause of the program abnormality and correct the program. After the program correction, the actuator and the work are returned to the state (position) before the stop by the switch operation panel 6, and the simulation is continued. Such recovery can be performed because the states of the actuator and the work at the time of the stop are known, and it is not necessary to restart the simulation from the beginning.

In addition, while verifying (simulating) the control program during the normal operation of the equipment, it checks how the control program works when there is an equipment abnormality (power failure, actuator abnormality, etc.). That is, in step A6, it is checked whether or not all the verification items set for the simulation when the equipment is abnormal have been completed.

If the verification is not completed, the process proceeds to step A7, where the set equipment abnormality is generated. When the equipment abnormality is of a nature that causes the equipment to stop operating, and when the control program stops the control at the scheduled step,
This means that there is no program error. In that case, the switch operation panel 6 is used to manually restore the state before the stop.
The simulation is continued by removing the equipment abnormality, and the existence of the program abnormality is checked (step A).
7 to A9). This verifies whether or not the operation of the equipment can be resumed when the operation is interrupted.

When the simulation cannot be continued, it means that there is a program abnormality, and after the program is corrected (step A5), the simulation is continued (step A3). If the simulation can be continued, it is determined that there is no abnormality in the program, and the process proceeds to the next verification (step A9 → A3).

On the other hand, if the control program does not stop the equipment as scheduled in step A7, it means that the program is abnormal. After manual recovery, the program is corrected and the process proceeds to the next verification (step A8 →
A9 → A5 → A3).

In step A7, when the equipment abnormality is of a nature that does not require the equipment to stop, if the equipment does not stop, there is no program error, and if the equipment stops, there is a program error. As in the case, the process proceeds to the next verification, or the program is corrected and the process proceeds to the next verification.

As described above, when the simulation has been completed for all the verification items, the simulation ends (step A6 → A10).

In the above simulation flow, the simulation is started after the abnormality setting by the abnormality setting program 9 is performed in advance. However, the simulation is appropriately stopped during the simulation for verifying the program in the normal operation. Then, the abnormality may be set, and the simulation may be continued to check for the presence or absence of the program abnormality.

<Simulation of Work Using Three-Dimensional Model> During the simulation by the simulator-side PLC 4, the timing chart generation program 18 inputs and outputs the equipment-side PLC 1 based on the operation command signals and the pseudo signals fetched from the address conversion programs 11 and 12. A timing chart of the output operation is generated, and the memory 19 stores the timing chart. When a program abnormality is found in the above simulation, a timing chart is generated and stored by the corrected program.

In the above simulation, since the program verification at the time of equipment failure is inserted in the middle of the program verification at the time of equipment normal operation, the obtained timing chart includes the input / output operation of the equipment-side PLC 1 at the time of equipment failure. become.

After the above simulation, three-dimensional CAD
The system 10 reads a timing chart from the memory 19 based on a command given from an external input device and converts the file format into a file format for a three-dimensional CAD system. Perform a work simulation using a three-dimensional model.

Since the timing chart used in the work simulation directly reflects the input / output operation of the equipment-side PLC 1, the work simulation is based on the actual movement of the equipment controlled by the equipment-side PLC 1 program. It will be in line with. Therefore,
The reliability of the interference check between the actuator, other equipment, and the workpiece by the interference check program is high.

When it is detected by the interference check section that predetermined interference has occurred, it is possible to confirm whether or not the interference is an inevitable interference with the work on the workpiece by the display. If the interference is abnormal, the timing chart will be corrected to re-verify whether such interference occurs.

Even when no interference is detected by the interference check unit, the movement of the actuator or the work in the work simulation is displayed on the display.
It is possible to check on the display whether there is a risk of interference when actually operating the equipment, or whether there is no waste in the movement of the actuator or the work, and correct the timing chart as necessary. Alternatively, it can be a trigger for changing the layout of the equipment.

Further, since the timing chart includes the operation timing at the time of equipment abnormality, the operation of equipment / work at the time of abnormality occurrence and manual recovery can be performed without separately preparing a timing chart dedicated to equipment abnormality. Can be confirmed.

When the timing chart is corrected, the correction is separately reflected in the program of the equipment-side PLC 1.

In the work simulation using the three-dimensional model, a series of processes for the work of the equipment can be continuously performed according to the timing chart. However, the work simulation can be performed in several steps. It is also possible to prepare a timing chart for normal operation and a timing chart for equipment abnormality, and separately verify the operation.

The simulator-side PL of the above embodiment
C4 simulates a change in the state of the actuator and the work, calculates the change state at predetermined time intervals, and generates a pseudo signal based on the result, but responds to various operation commands from the equipment-side PLC. A response time for providing a pseudo signal may be set, and the simulation may be executed only by managing the response time.

[Brief description of the drawings]

FIG. 1 is a diagram showing a hardware configuration of a simulation device according to an embodiment of the present invention.

FIG. 2 is a block diagram showing a configuration of the simulation apparatus.

FIG. 3 is a diagram showing an example of a timing chart.

FIG. 4 is a diagram showing a work simulation screen using a three-dimensional model.

FIG. 5 is a diagram showing a flow of a simulation by a simulator-side PLC.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Equipment side PLC 2 Simulation apparatus 3 Communication line 4 Simulator side PLC 5 Computer 6 Switch operation panel 7 State calculation means 8 Pseudo signal generation means 9 Abnormality setting program 10 3D CAD system 11 Input address conversion program 12 Output address conversion program 13 operation setting program (operation setting means) 14 actuator position calculating means 15 work position calculating means 16 detector setting program 17 pseudo signal generating program 18 timing chart generating program

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Naofumi Suzuki 3-1 Shinchi, Fuchu-cho, Aki-gun, Hiroshima Prefecture F-term in Mazda Co., Ltd. (Reference) 3C007 AS23 BS10 JS02 LS08 LS20 MT01 5H220 AA05 BB12 CX09 JJ02 JJ19 JJ24 JJ34 KK08 LL06 MM03 5H223 AA06 CC03 CC08 DD03 EE06 EE19 FF05

Claims (2)

[Claims] 1. A simulator for generating a pseudo signal related to the operation of a facility in response to an output of a sequencer for controlling the facility and providing the pseudo signal to the sequencer, simulating the facility operation by a program of the sequencer. A timing chart for the input / output operation of the sequencer based on the input / output operation of the sequencer, and performing a work simulation using a three-dimensional model for the work of the equipment based on the timing chart. 2. A sequencer for controlling equipment, and a pseudo signal related to the operation of the equipment is generated and given to the sequencer in accordance with an output of the sequencer for simulating equipment operation by a program of the sequencer. A simulator; a timing chart generating means for generating a timing chart of the input / output operation based on the input / output operation of the sequencer during the simulation; and a work simulation of a three-dimensional model for the work of the equipment based on the timing chart. A simulation apparatus comprising: a three-dimensional simulation means for executing.