virtual methods in programming and simulation of programmable
TRANSCRIPT
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
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 2
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
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 3
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
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 4
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
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 5
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
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 6
Conventional programming versus VR interface and visual programming
Intuitive connection of inputs and outputs
in VR Textual PLC programming
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 7
Three applications of VR based simulation
LD b1AND b2ANDN b3ST bo
PLC-Code_1
PLCfacility (real)
LD b1AND b2ANDN b3ST bo
PLC-Code_3
LD b1AND b2ANDN b3ST bo
ProgrammingEnviroment
PLC
LD b1AND b2ANDN b3ST bo
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
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 8
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
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 9
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
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 10
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
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 11
Step1: Configuration of the facility layout
Select Actorsor Sensors
Select geometry
1 2
Arange components
3
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 12
4 5
Step 2: Virtual Wiring(only needed if the PLC CODE already exists)
Connect I/O with virtual components
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 13
Step3: Dialogue supported programming of PLC functionalities
Selected Actor
SelectedFunction
6
7
Define the logic8
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 14
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
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 15
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