VIRTUAL METHODS IN PROGRAMMING AND SIMULATION OF PROGRAMMABLE

Institut für Werkzeugmaschinen und Betriebstechnik Universität Karlsruhe (TH) o. Prof. Dr.-Ing. H. Weule, o. Prof. Dr.-Ing. D. Spath, Prof. Dr.-Ing. J. Schmidt Kaiserstr. 12 , D-76 128 Karlsruhe Tel.: +49 (721) 608 - 2441 / 4011 1

VIRTUAL METHODS IN PROGRAMMING AND SIMULATION OF PROGRAMMABLE LOGIC CONTROLLED

MAUNUFACTURING SYSTEMS

VIRTUAL METHODS IN PROGRAMMING AND SIMULATION OF PROGRAMMABLE LOGIC CONTROLLED

MAUNUFACTURING SYSTEMS

o. Prof. Dr.-Ing. Dieter SpathDipl.-Ing. Robert Landwehr

Institute for Machine Toolsand Production Science

University Karlsruhe (TH), Germany


Problems of a sequential process chain for planning of PLC software

Customer

Marketing

Mechanical construction

Controlling technology

Work preparation

Production and assembly

Initial operation

Documentation

After-Sales Service

Difficulties in communication due to organisational and spatial separation

Different qualifications, ways of thinking and understanding

Uncontrolled storage and passing on of information

Large number of changes and insufficient personnel to cope

Insufficient co-ordination of work in time and sequential working

Time pressure due to numerous subsidiary tasks (e.g. offers, starting up and service)

Insufficient inclusion of electrical construction into concept phase (insufficient real team work)

Insufficient description of functions (large number of enquiries and misunderstanding)

Mechanical engineering

Control engineering


Problems at Initial Operation

electrics /control

enginee-ringabout

15p.c.

up toabout90 p.c.of time

controlengineering

total durationof project

initialoperation

softwareerrors

• defective or missing latches

• incorrect procedures

• wrong S/R of steps, defectiveskips

• wrong S/R of markers/signals

• multiple usage of variables

• error in running time(exceeding the cycle time)

• miscellaneous errors(typing errors, oversight)

of thisup toabout70 p.c

typical errors

initialoperation

pneumatichydraulic CAD part-

listsassembly

plansPLC

late evaluation of system design leeds to great time losses

PLC


Virtual Reality as the Integrating Medium

3-Dimensional presentationof complex systems withthe possibility of

interaction with the model

immersion

cooperation

communication

Animation

SimulationOnline

NumericSimulation

Virtual Reality

Interaction

WalkthroughVisualization


Advantages of VR interface

Cessation of 3D-2D abstraction for visualisation, navigation and interaction

Experiencing model utilizing sensoric feedback

Observation of critical rocedures from the point of view of time

Possibility of excluding real restrictions

Direct application of heuristic problem solving behaviour

Spatial distribution of planning competence

Increasingly complex tasks during process and product planning

Insufficiently realizedman/machine interfaces

Understand

See

Experience

Decide

Necessity of simulation before realization


Conventional programming versus VR interface and visual programming

Intuitive connection of inputs and outputs

in VR Textual PLC programming


Three applications of VR based simulation

LD b1AND b2ANDN b3ST bo

PLC-Code_1

PLCfacility (real)


PLC-Code_3


ProgrammingEnviroment

PLC


PLC-Code_2

VR-based simulation enviroment

1

2

3

PLC CODE built in a common PLC Programmingenvironment can be simulated ONLINE.

Existing PLC Codes can be simulated byconnecting the real PLC and the virtual model

PLC Codes can be generated and validated with the virtual model


Structure of the system

yes

no

FacilityComponents

LibraryModelling in

CAD

Modelling in VR

Parameterisa-tion of functions

Logicalconnection S/A

level

AWL computer

Control

rough test of facility

OEC 1131programms

Layout

No. I/Os

Procedurescript

Simulation

ok?

Step identifier

Configure

Sequentialconnectingprocedures

Overall facility

VR-PLC PLC-VR

Programming-environment

Docs

Actions

Output

Input

Correction

Legend

Onl

ine

coup

ling

via

OPC

(DC

OM

)

no

Simulation?

FBS script

Symbol file

yes


Aggregation of a technical system in the VR system

production systemproduction system

drilling stationdrilling station milling stationmilling station sorting facilitysorting facility

Conveyorbelt

Conveyor belt drilling machinedrilling machine milling machinemilling machine

CB-forward

CB-forward CB-stopCB-stop Terminalswitch

Terminalswitch

lightbarrier

lightbarrier

conveyor belt(components)

conveyor belt(components) profilesprofiles Switching

cabinet

Switchingcabinet

work place

work place

Facility structure (geometry)

Facility levelFacility level

Procedural level

Procedural level

Functionallevel

Functionallevel

Actor/sensor level

Actor/sensor level

Geometry/Module levelGeometry/

Module level


Creating and validate a virtual model and ist PLC Code in four steps

Step 1: Configuration of the facility layout

Step 2: Virtual Wiring(only needed if the PLC CODE already exists)

Step 3: Dialogue supported programming of PLCfunctionalities

Step 4: Validate the PLC-Code via OnLine-Connection

TEST

1 2 3 4

1

2

3

4


Step1: Configuration of the facility layout

Select Actorsor Sensors

Select geometry

1 2

Arange components

3


4 5

Step 2: Virtual Wiring(only needed if the PLC CODE already exists)

Connect I/O with virtual components


Step3: Dialogue supported programming of PLC functionalities

Selected Actor

SelectedFunction

6

7

Define the logic8


Control of the real model

SOFT-SPS

Control of the virtual model

AnySIMopen

Realität

Industrial Fieldbus

OLE for Process Control

LoLi (LogicLink)(VC++ PRG)

VREnviroment

Former Way of testing the PLC Code

Test the PLC Codevia OnLine Conection SPS VR

Virtual Reality

Comunication-processor Distributed I/O s

Reality

OLE for Process Control

Previous way of testing the PLC Code

Test the PLC-Codevia OnLine Conection SPS VR

Step 4: Validate the PLC-Code via OnLine-Connection

This Program provides the connection between the PLC and the VR enviroment

8

SOFT-SPS


Next Steps

Further exchange of components geometry with CAD Systems

Create an simulate a PLC-Code for a CNC (Sinumeric 840D)

Evaluate the concept with a big production System of ROBERT BOSCH GmbH, Homburg, Saar

establishing a data structureaccording to DIN IEC 1131

VIRTUAL METHODS IN PROGRAMMING AND SIMULATION OF PROGRAMMABLE

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