I, Overview
1.1 General Introduction
It is planned to configure a set of “virtual simulation training software for automatic
production line installation and adjustment technology”, which integrates 3D resource
learning, virtual simulation training for production line installation and adjustment
technology, and process evaluation and assessment. It is suitable for the theoretical and
practical teaching of mechatronics technology and training. Students’ professional and
technical skills in equipment and structure cognition, tool use, mechanical assembly, gas
debugging, control system design, parameter setting and debugging, programming and
configuration monitoring, operation and maintenance, etc.
1.2 Simulation object
The virtual simulation training software for automatic production line installation and
adjustment technology takes “automatic production line installation and commissioning
training device” as the object to perform 1: 1 3D modeling, restore the structure and
function of the device, and simulate various links of practical training operations. It can
realize the equipment selection, mechanical assembly, line connection, and system
debugging of five workstations, and can realize the policy control of each site in the virtual
scene through the PLC controller or Botu software.
[Note: The simulation object can be specially customized according to the actual needs of
school teaching, depending on the real hardware device it owns, and used in conjunction
with the real hardware device. ]
1.3. Advantage
(1) The problem of difficult teaching evaluation is solved, the system automatically
monitors the learning status of the students, collects key skills information completed
during the simulation training process, automatically uploads it to the platform, and
generates performance information;
(2) Contextualized teaching, which solves the problem of less scene resources and poor
teaching experience in the teaching process;
(3) Solve the problem that only a small number of people operate in the teaching process,
and meet more people to conduct training at the same time;
(4) Solved the current teaching situation where only hardware in the training room is
difficult to use, or it is difficult to restore and restore after the use;
(5) Solved the problems of high equipment consumables cost, equipment damage, and
low repeated utilization during the teaching process;
(6) Solve the problem of personnel safety, repeated training in the virtual simulation
environment, and synchronization of safety precautions;
(7) The software virtual simulation remote update and hardware modular expansion
structure solve the problem of equipment update iteration.
II Software Description
Automatic production line installation technology virtual simulation training software,
through the two modes of learning, practice, and assessment, covering all aspects of user
training and teaching, so that users can complete the entire training process using the
software, that is, digital resources can be multidimensional Understand the training
process, and through virtual simulation to achieve repeated exercises and test the effect
of learning.
2.1, learning mode
After the user enters the learning mode operation interface, the product provides task
sources, task descriptions, ability goals, related knowledge and skills, knowledge
preparation, equipment cognition, theoretical learning, and more.
(1) Training purpose: To understand the basic skills, key skills, knowledge goals, and
professional attainment goals that should be mastered after the training task is completed;
(2) Relevant knowledge and skills module: Provide professional theoretical knowledge
related to training tasks.
(3) Device recognition module: Contains the equipment used for each training task and
displays equipment details. You can view the device information, such as the product
description of the device 3D model), product descriptions, and other product specifications;
the 3D model exhibition can be rotated 360 ° at any time, can be zoomed in and out, and
can be moved at any position to recognize the shape of the device. For complex
equipment, the internal structure of components can be decomposed through exploded
diagrams to help students learn the principle of internal structure of components.
Cognitive components include mechanical body structural components, pneumatic
components, sensing test units, motion execution units, control and information units,
power distribution components, tools, and other accessories (buttons, indicators, terminal
strips, wires, screws) Wait.
① Pneumatic components: Pneumatic components required at each site, including but
not limited to air compressors, various types of pneumatic solenoid valves, various types
of execution cylinders, etc.
② Sensing test unit: It refers to the sensing test elements required at each site, including
but not limited to magnetic switches, diffuse photoelectric switches, inductive proximity
switches, fiber optic sensors, etc.
③Motion execution unit: the execution mechanism required by each station, including but
not limited to two-position five-way single electric control solenoid valve (retractable
cylinder solenoid valve, stamping cylinder solenoid valve, blocking cylinder solenoid valve,
ejection cylinder solenoid valve) 2, two-position five-way double electric control solenoid
valve (finger cylinder solenoid valve, swing cylinder solenoid valve), stepper motor, servo
motor, variable frequency motor, etc.
④Control and information unit: the equipment included in the control system, including but
not limited to PLC controller (default S7-1200, other S7-200, S7-300, S7-400, S7-1500
optional), servo driver, step Drive, inverter, etc.
⑤ Power distribution components: Power distribution related equipment, including but not
limited to leakage protection switches, 2P / 3P air switches, DC24V / 6A regulated power
supply, etc.
2.2 Practice Mode
After the trainee enters the practice mode interface of the training task, the system
provides a 3D simulation training scene. The trainee can roam the scene arbitrarily
through the mouse or keyboard control perspective, and can perform equipment selection,
assembly, wiring, debugging and other training. At the same time, the system provides
instructional videos, operation manuals, system wiring diagrams, demonstration operation
tasks and other related materials. By showing the equipment structure, wiring effects,
operation guidelines and function demonstrations, users can understand the task content
and scenes, and master the practical methods.
2.2.1, equipment selection
Contains all kinds of components required by the course. Users can choose to use them
independently. According to the content and requirements of the current experiment,
choose the appropriate type of components or equipment to complete the training tasks.
2.2.2 Mechanical assembly
The components and equipment of the selected model can be installed and placed in a
three-dimensional scene. Installation methods can be divided into module assembly,
single station assembly, and whole station assembly.
① Module assembly: The required components can be placed in the three-dimensional
scene in the list of uninstalled equipment, and assembled and fixed in accordance with the
requirements. It is then saved locally for easy recall when the workstation is assembled.
②Single-station assembly: The components of the “uninstalled equipment list” can be
directly placed in a three-dimensional scene for assembly, and finally assembled into a
workstation; it can also call the assembled module, and then assemble the module into a
workstation. Including: feeding station assembly, processing station assembly, assembly
station assembly, sorting station assembly and conveyor station assembly.
③ Whole station assembly: The assembled five workstations can be fixed and installed on
the workbench in the three-dimensional scene according to the space size of the physical
platform to complete the whole station assembly.
2.2.3 Electrical and pneumatic connections
The system can determine the type of the device’s wiring port. If the type of the device’s
port does not match the wire, it cannot be connected. Students can make free wiring by
selecting the wire materials. The wiring mode includes gas connection and line
connection.
①Pneumatic connection: Click the “Connect” button on the toolbar to pop up the “Wire
property setting interface”, and then select “Trachea” in the “Line type” drop-down list.
Select the start and end points of the trachea in the scene, and the trachea connection
effect will appear.
②Electrical wiring: Click the “Connect” button on the toolbar to pop up the “Wire property
setting interface”, and select “Wire” from the “Line type” drop-down list. After setting the
line type, color, and cross-sectional area, select the start and end points of the wire in the
scene, and the connection effect of the wire will appear. An IO port allocation table is
generated to indicate the devices connected to the inputs and outputs of the PLC.
2.2.4 System debugging
After the user completes the correct wiring in the practice mode, the following virtual
devices can be debugged.
1 Virtual servo driver: It can complete the panel operation training and parameter setting
functions, and can realize the position control function according to external instructions.
② Virtual stepping motor driver: it can complete the training content of the DIP dial switch
setting parameters, and realize the speed and displacement control by receiving the pulse
signal and direction signal from the external PLC.
③Virtual inverter: It is possible to set parameters and view parameter values on the virtual
inverter, to control the motor speed with the panel, to control the motor speed with an
analog terminal, to control the motor speed with multi-speed, and to control the motor with
a potentiometer Speed; a table of “Setting values of inverter parameters” can be derived.
④Virtual pneumatic system: It can adjust the speed regulating valve on the cylinder to
change the speed of the cylinder’s extension and retraction; you can change the rotation
angle of the rotary cylinder by adjusting the length of the screw; you can check the airflow
direction of the solenoid valve in the operating state; The telescopic state of the cylinder
push rod can be judged by the change of the indicator signal of the magnetic switch; the
state of the solenoid valve can be controlled manually; the knob on the filter pressure
reducing valve can be adjusted to change the air pressure state, and the current air
pressure value can be viewed through the dial.
⑤ Virtual sensor: can perform signal output normally open / normally closed setting; can
set to detect objects of different colors; can indicate the power-on state of the sensor and
the state of the object through different indicators; can detect the power-on state of the
sensor through a virtual multimeter , The state of the detected signal;
⑥ Virtual basic electrical control components: Components include common electrical
components such as circuit breakers, contactors, and buttons. Their functions in the
scene are developed according to the electrical characteristics of the physical objects,
and corresponding actions can be performed according to human operations or signal
instruction input.
⑦Virtual scene and drawing linkage: The gas path state in the virtual scene will be linked
with the gas path diagram. In the virtual scene, the sensors, buttons, etc. at the input end
of the PLC and the state of the solenoid valve at the output end will be linked with the
electrical schematic diagram.
2.2.5 PLC programming
Supports communication with PLC and Broadway software to realize I / O point
configuration and PLC programming. PLC controller supports Siemens S7-200, S7-300,
S7-400, S7-1200, S7-1500 and other series, and can Supports two communication
methods:
(1) Virtual and physical simulation training: support virtual and real interaction with real
PLC controller equipment through TCP / IP (Communication 1), support I / O point
allocation, PLC programming and human-machine interface, etc. Need PLC controller to
work together with software)
(2) Direct communication between the simulation software and Botu: The self-developed
software plug-in can be used to support the communication between the simulation
software and the Botu software (or STEP Basic) (communication two), so as to meet the
programming training of PLC.
2.3, assessment mode
After the trainee enters the assessment mode interface of the training task, the system
provides 3D simulation training scenarios. The trainee is required to complete the
equipment selection, assembly, wiring, programming and debugging according to the
assessment criteria of the mission. Each training task has a specific assessment scoring
standard assessment item, and each completion of the assessment item shows that the
assessment passed; when all assessment items have passed, the task assessment
passes. The system will automatically complete the result evaluation and automatic
scoring, and complete the process evaluation and assessment.
III, basic functional requirements
3.1 Support multiple teaching modes
It has three modes of learning, training and examination, covering all aspects of user
training and teaching. It can learn the training process in combination with digital
resources in multiple dimensions, and iterative training can be achieved through virtual
simulation. At the same time, it has the function of process evaluation and evaluation to
achieve the effect of learning purpose.
3.2, Support online virtual simulation experiment training
Combined with the virtual simulation comprehensive training teaching platform, the virtual
simulation training software has an online virtual simulation function, which can make
students free from the space limitations of the classroom, and can perform online
simulation learning and training at any place and at any time.
Be able to enter the function and operation guide mode to guide students to learn how to
operate.
3.4 Support coordinate display function
Taking the bottom left corner of the workstation desktop as the origin of the coordinates,
the devices moving in the scene will each have a dynamic coordinate point. After the
device is installed correctly, the distance between the point and the two sides of the table
will be displayed, and the coordinate distance can be set to show and hide .
3.5, Support installation of devices in virtual space
The operation interface has a device library, and students can choose the equipment
required for the experiment and install and operate as required;
3.6, Support the selection and use of virtual tools
The operation interface is provided with a tool auxiliary material library, and students can
choose the corresponding tools and materials on their own.
3.7, Support the use of virtual instrumentsStudents can select various types of virtual instruments to measure the quantity or status
of system lines or equipment, including but not limited to multimeters, pressure gauges,
and oscilloscopes;
3.8, Support fault setting and troubleshooting
Various types of electrical faults can be set inside the simulation scenario. Students will
submit the fault information after the fault is eliminated and manually remove it.
3.9, Support video recording function
This product supports recording the training operation process into a universal Mp4 format
video file and saves it to a specified location locally. It can be used to submit the recorded
video file as an attachment when submitting an experiment report; it also supports lecture
and micro-lecture Recording to support the construction of the resource library project.
3.10, Support export training operation data
During the training process, the student’s parameter settings (such as the parameter
settings of the inverter) and I / O point assignments can be exported as data files, which
can be used to write training reports.
3.11, Support saving experiment snapshots
Students can save scene files locally; they can also open previously saved local files.
Under the same account, save the current experimental task node as an experimental
snapshot for quick access next time. Saving the experiment snapshot again will overwrite
the last saved result.
3.12, Support timing function
In the assessment mode, the timing function takes effect, and records when the user
completes the assessment operation.
IV Simulation training project
4.1, mechanical assembly
(1) Mechanical assembly of the feeding station
(2) Mechanical assembly of processing stations
(3) Mechanical assembly at the assembly station
(4) Mechanical assembly of the sorting station
(5) Mechanical assembly of the conveying station
4.2 Sensor debugging
(1) Magnetic switch debugging training
(2) Training of diffuse reflection photoelectric switch
(3) Inductive proximity switch debugging training
(4) Commissioning and training of rotary encoder
(5) Fiber optic sensor debugging training
4.3 Cylinder debugging
(1) Pen cylinder training
(2) Commissioning and training of thin cylinders
(3) Finger cylinder debugging training
(4) Commissioning and training of double-rod cylinder
(5) Commissioning training of rotating cylinder
4.4 Frequency conversion and servo debugging
(1) Installation and commissioning of the inverter system
(2) Servo system installation and commissioning
4.5 Workstation debugging
(1) Commissioning and training of feeding station
(2) Commissioning and training of processing stations
(3) Commissioning training of assembly station
(4) Commissioning and training of sorting stations
(5) Commissioning and training of transmission station
(6) Joint commissioning and training of feeding station, sorting station and conveying
station
(7) Five stations joint debugging and training