Design And Implementation Of Virtual Commissioning System For Intelligent Manufacturing Production Line

With the concept of "Industry 4.0" proposed,all countries in the world are vigorously promoting intelligent manufacturing,and the mode of manufacturing is gradually shifting toward the direction of intelligence.Before the intelligent manufacturing production line put into use,operators need to go to the site to debug equipments,but the on-site debugging has problems of high cost,long cycle,high risk,etc.Considering the drawbacks of on-site debugging,a virtual commissioning system for intelligent manufacturing production line is designed and implemented.Industrial control equipments such as PLC,robot controller and numerical control system are used to debug the intelligent manufacturing production line simulated in the simulation software.The main research contents of this thesis include the following aspects:(1)Considering the speed of system data transmission and compatibility between device interfaces,physical industrial Ethernet is used to integrate communication between industrial equipments and PC.Based on the open source component or the PC SDK provided by the device manufacturer,device drivers are developed through the form of dynamic link libraries.Device drivers serve as the basic component of data acquisition for the virtual commissioning system,and provide the ability to connect and interact with PCs and devices.(2)According to the development of device driver,the user-friendly PC-side interactive control software is designed for data interaction between the industrial control device and the simulation software.The interactive control software adopts the OSGi.NET plug-in framework.According to the classification of devices,each device application is developed independently in the form of a plug-in.Each device plug-in includes a data acquisition module,an interaction interface module,and a data cache module.The interaction interface is used to observe the device data and configure virtual and real interaction signals.The thread pool implements multi-threaded task management.Redis is used for caching of virtual and real device signals.The development of plugins improves the scalability and versatility of the software.(3)The intelligent manufacturing production line scene is simulated in the simulation software,and the control signals obtained in the Redis database through the Python script program is used to perform virtual commissioning on the virtual model.Combining the designed system software,ABB robot system is created in RobotStudio and RAPID program is writed to realize multi-robot demolition and palletizing task in simulation software.PLC ladder program,robot program and G code is written to run Intelligent manufacturing processing system in the simulation software.Then these programs are downloaded to the field device to verify the effectiveness of the virtual commissioning.The results of virtual commissioning and field experiments show that the virtual commissioning system for intelligent manufacturing production line can find and correct the unreasonable control program,reduce the risk of on-site debugging,shorten the time of on-site debugging,and provide an effective solution for the rapid launch of intelligent manufacturing lines.