Design And Implementation Of Logistics Production Line Training System Based On Virtual Debugging

With the rapid development of industry 4.0 and the wide application of virtual debugging technology in industrial production,the operation ability and training methods of production line trainers need to meet higher professional requirements.The traditional production line training mainly adopts theory learning,field operation and other long cycle,high risk methods.Meanwhile,virtual debugging technology has fewer applications and monotonous function in the training system,and it is difficult to achieve a good effect of skill training.In view of the disadvantages existing in the current traditional training and the poor interactivity of production line training system.Based on the training device of logistics production line of a cigarette factory,by using Unity3 D simulation technology and production line operation mechanism.This thesis designs and implements a logistics production line training system based on virtual debugging.The system uses modules including PLC programming,production line operation demonstration and production line fault debugging to perform virtual debugging on the simulated logistics production line in the simulation platform,and returns the feedbacks of virtual training.The main contents of this thesis are as follows:(1)Based on Maya modeling software,the equipment of logistics production line is modeled,and the virtual simulation model of production line is built.Based on the Unity3 D engine as the development platform for the virtual realization of the production line,the system adds PLC I/O ports and C# behavior script files of virtual equipment.The stability of data interaction between virtual PLC and simulation platform of production line is improved through socket communication protocol.(2)After the function analysis of Virtual PLC,the virtual PLC control system is developed with Winform framework.The function of ladder diagram editing module is studied based on IEC61131-3 specification.The virtual PLC establishes ladder diagram syntax rules and realize ladder diagram syntax logic check function.The information of ladder diagram is stored by adjacency matrix,which meets the requirements of dynamic programming of ladder diagram.The series-parallel logic algorithm of ladder diagram was studied.The matrix information is mapped into a directed graph to obtain the predecessor successor relationship of each control of ladder diagram,and then the directed graph is transformed into a binary tree structure to obtain the series-parallel logic relationship.The dynamic logic simulation of ladder diagram is realized by data structure conversion.(3)The thesis investigated and analyzed the typical fault data of the production line,established the fault database based on SQL Server 2014,and stored the fault information and troubleshooting methods.Moreover,the typical fault tree model of the production line is established.A variety of production line fault phenomenon demonstrations are made by using animation machine.Based on the fault tree model,the top-down fault random combination method was studied,and the function of multiple random fault demonstration is realized.The data transmission between virtual debugging tool and fault model is realized by using ray collision detection technology and virtual interaction mechanism.Through PLC ladder program and C# script to control the operation of the production line simulation system.The effectiveness of virtual debugging is verified.(4)A virtual training evaluation method is developed according to expert opinions.The thesis uses the Event System mechanism of Unity3 D to record the students' operations in the virtual scene.The generation method of practical operation sequence based on the mathematical model of finite state machine is investigated.By comparing and matching the standard sequence with the trainees' operation sequence,the studied system obtains the students' performance and evaluation of this operation training.The results of virtual debugging show that the training system of logistics production line based on virtual debugging in this thesis is helpful to PLC programming training,demonstration of typical fault phenomena of production line and virtual debugging operation of fault.The system reduces the risk and cost of on-site training,and provides an effective s for the training method of production line operators.