In-depth application of digital simulation to create a “virtual debugging” acceleration engine for intelligent logistics

At present, proven digital intelligence technologies have arrived and fostered innovation in many industry segments. In the field of robotics and logistics integration, the in-depth application of technologies represented by digital twin simulation has significantly improved the company’s efficiency across design, commissioning, and operations.

Over the years, the SIASUN Robotics Automation Co., Ltd. (hereinafter referred to as “SIASUN Robotics”) has been responsible for many benchmark projects for leading domestic and foreign users in various industries, thanks to its leading mobile robots and intelligent warehousing and logistics solutions. In the critical electrical debugging process, the company takes advantage of Rockwell Automation’s Emulate3D™ digital simulation platform, opening the door to “virtual debugging.”

Digital twin simulation: A better solution for electrical debugging

Today, modern production requires a great deal of automation equipment, while traditional installation and debugging requires mechanical, electrical, automation, and other engineers to work together on-site in the workshop, which is time-consuming and labor-intensive. Not only is this costly, but the lead time is also very long when trying to solve problems that arise during the debugging phase. The challenge faced by many enterprises today is how to verify system design solutions in a simple, intuitive, efficient, and cost-effective manner.

In the field of logistics integration, most enterprises still use traditional electrical debugging, which is increasingly difficult to meet the market demand for agile response and complex applications. Considering SIASUN Robotics as an example, its previous rubber roll conveyor system utilized a cargo collision prevention solution to ensure the accurate positioning of the cargo with the aid of collision-stop delay. However, due to the irregular structure of the shelves, many complex dynamic geometry and edge impacts interact in the physical world, making it challenging to achieve design goals, and traditional debugging was unable to quickly verify the avoidance and cargo space calculation programs.

Fortunately, the in-depth application of digital twin technology in recent years has expanded the scope of traditional mechanical simulation and brought more attention to the “virtual debugging” function. Overall, thanks to “virtual debugging,” auxiliary design can be completed, and program logic, action interference, and production process can be verified before the equipment is placed at the site. It not only reduces debugging time and cost, but also enables enterprises to identify potential improvement opportunities, making the equipment even better in terms of automation and other functions.

Meanwhile, “virtual debugging” has increased the proportion of software usage in the electrical debugging process, which mirrors the current trend of intelligent development, and has become a unique area for SIASUN Robotics to enhance its digital competitiveness.
 

Outstanding simulation software facilitates breakthroughs in three steps

In response to the difficulties faced by factories in verifying a large number of non-standard automation system programs, SIASUN Robotics has chosen to work with Rockwell Automation, with the aim to complete its digital and intelligent upgrading with the aid of Emulate3D, the leading electrical simulation software.

During the implementation of the project, Rockwell Automation takes a three-step approach to realize virtual debugging efficiently and with high quality:

① Real model construction: As is well known, the final result of virtual debugging is directly impacted by the accuracy of the simulation model. Therefore, in the modeling session, for a realistic effect, the project team has built a real mechanical model of the stacker and other systems using Emulate3D based on the dimension settings (length, width, height) and position layout of the shelves.

It is well known that Emulate3D supports the import and export of many mainstream 3D-format files. The model can also be hierarchically divided based on action attributes and simplified by merging static objects, which provides significant convenience for the customer’s future editing.

② Action addition: For a better connection with PLC, custom scripts and data interfaces can be created for the imported model by using the QuickLogic graphical language of Emulate3D software. Of these, the output signals at the customer's site mainly involve high- and low-speed switching of the elevator, position control of the stacker, etc., while the input signals involve limit switch feedback of the elevator, position feedback of the stacker, etc.

Thanks to Emulate3D's efficient development system and simple operation steps, SIASUN Robotics completes data and logic mapping faster, which also lays a solid foundation for quickly and accurately implementing the virtual debugging function.

③ Virtual debugging: After the completion of action addition, the project team connects the simulation model created by the software to the PLCs of the conveyor and stacker respectively to simulate the inbound and outbound actions through the interaction between each PLC and the model. Meanwhile, the team further programs human actions by using teach-in points to specify the target positions of walking and arm movements to achieve actions such as walking, carrying goods, and clicking buttons.

The project is currently in the trial operation phase. With the powerful performance of Emulate3D and Rockwell Automation’s professional engineering implementation services, SIASUN Robotics successfully verified its cargo space calculation and avoidance programs on the computer, thereby avoiding irrational dynamic geometry and edge impacts and making on-site debugging more efficient.