CN109326003B - Factory three-dimensional monitoring system based on virtual simulation - Google Patents
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Abstract
The invention relates to a method for realizing a three-dimensional factory monitoring system based on virtual simulation, which comprises the steps of constructing a digital model of actual physical equipment by utilizing Visual Components virtual simulation software, developing a set of data acquisition system by combining a communication interface and a protocol of the specific physical equipment, acquiring open data, adding corresponding attributes and behaviors to the digital model established in the simulation software according to the acquired data, calling a Python API carried by the simulation software to realize data mapping of each attribute between each attribute and the data acquisition system, and reproducing the attributes and behaviors of the actual equipment in the virtual simulation software, playing a role of remote monitoring of the actual physical equipment and visually displaying the working condition of the current equipment.
Description
Technical Field
The invention belongs to the technical field of intelligent equipment, and particularly relates to a method for realizing a three-dimensional factory monitoring system based on virtual simulation.
Background
In recent years, with the increasing level of equipment intelligence, informatization and population dividend, advanced manufacturing strategies and manufacturing modes such as 2025 and industrial 4.0 in china emerge, and the realization of real intelligent manufacturing is one of the targets commonly pursued by various countries at present. One of the bottlenecks in achieving this goal is how to achieve interaction and fusion of the physical world and the information world in production and manufacturing, and the digital twin technology has attracted much attention as an effective method for achieving real-time interaction and fusion of the physical world and the information world.
The digital twin is to fully utilize data of a physical model, sensor updating, operation history and the like, integrate a multidisciplinary, multi-physical quantity, multi-scale and multi-probability simulation process and complete mapping in a virtual space so as to reflect various elements of corresponding physical equipment and real-time dynamic operation conditions in the whole life cycle, thereby realizing functions of system monitoring, operation and maintenance, process and system optimization, time prediction, simulation and the like.
At present, most of automatic production lines, automatic factories or workshops adopt MES systems to collect and monitor production equipment data, but the collected data are mostly equipment operation data, professional personnel are required to understand the equipment state represented by the data, the data presentation is not intuitive enough, and the operation state of the equipment is difficult to reflect intuitively; at present, a few enterprises apply a three-dimensional dynamic monitoring system, a model of equipment of the whole production line is established from the bottom layer through OpenGL, and the model and acquired data are interacted to realize three-dimensional dynamic monitoring, but the whole production line has numerous equipment, and the establishment of the equipment digital model from the bottom layer wastes time and labor, so that the development period and cost of the whole monitoring system are greatly increased, and the development of the whole monitoring system is not facilitated; in addition, the production process of a factory is often a dynamic and complex production process, and it is difficult to decide whether the whole scheduling plan is reasonable only by simple calculation, so that the production efficiency of the production line is not high, and each production device is not reasonably utilized.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a method for realizing a three-dimensional factory monitoring system based on virtual simulation, which is used for realizing the rapid development of a three-dimensional production line monitoring system.
The technical scheme adopted by the invention is as follows:
a method for realizing a three-dimensional factory monitoring system based on virtual simulation is characterized by comprising the following steps:
the method comprises the following steps: establishing a digital model of actual physical equipment by using digital factory simulation software Visual Components, establishing corresponding nodes according to the action condition of the equipment, and adding corresponding attributes and behaviors;
step two: acquiring data openly acquired by actual physical equipment, and developing a data acquisition system according to a communication interface and a protocol of the actual physical equipment;
step three: adding corresponding attributes and behaviors to a digital model established in Visual Components of digital plant simulation software according to the acquired data of the actual physical equipment;
step four: defining a data mapping mode of a data acquisition system and a digital model, adopting a TCP/IP protocol, adding a module which is communicated with a virtual simulation digital model in the data acquisition system, and sending acquired data to the virtual simulation digital model;
step five: calling a Python API development communication module provided by Visual Components software according to a data mapping mode of a data acquisition system and a virtual simulation digital model, and receiving acquired data;
step six: adding a PythonScript behavior in the virtual simulation digital model component, and defining corresponding processing logic of the virtual simulation digital model component after receiving data in the PythonScript behavior;
step seven: and operating the data acquisition system to acquire data in the physical equipment, connecting the data acquisition software in the simulation environment of the digital plant simulation software Visual Components, operating the simulation environment, transmitting the acquired data to the digital plant simulation software Visual Components in real time by the data acquisition system, receiving the acquired data in real time by the digital plant simulation software Visual Components, mapping the received acquired data into data in the digital model according to the mapping relation established in the fifth step, and correspondingly processing the digital model by using corresponding processing logic defined in the PythonScript behavior established in the sixth step after the data is received, so as to realize field equipment monitoring.
Further, the first step further comprises:
the used virtual simulation software is Visual Components software, and the process of establishing the specific digital model comprises the following steps: if the virtual simulation software Visual Components self-contained library contains the model of the actual physical equipment, detecting whether the sizes and the behaviors are matched with the actual physical equipment, if not, carrying out corresponding modification, if the virtual simulation software Visual Components self-contained library does not contain the model of the actual physical equipment, firstly establishing a three-dimensional model of the equipment in the three-dimensional modeling software, and then importing the three-dimensional model into the virtual simulation software Visual Components to define corresponding nodes, attributes and behaviors.
Furthermore, the data acquisition system described in step two is developed in a Winform framework by adopting C # language in a VS2015 development environment, and the system not only has a data acquisition function, but also has a function of controlling field devices.
Furthermore, the acquired data is data which can be acquired by a sensor installed on the field physical equipment and comprises displacement and speed.
Further, the attributes and behaviors added by the digital model in the third step specifically include: a shaping data attribute, a floating point data attribute, a boolean data attribute, a character data attribute, a Controller behavior, a Container behavior, a Signal behavior, a pythoncript behavior, and the like.
Further, in the sixth step, the processing logic of the simulation model component includes that when the collected information changes, the state of the simulation model is correspondingly changed, including the action information and the state information of each model, so as to realize one-to-one mapping between the collected data and the digital model data.
Furthermore, the data acquisition system is connected with the virtual simulation software through wireless or wired communication.
Further, in the seventh step, when the data acquisition system sends the acquired data to the virtual simulation software, the data acquisition system acquires data of the physical device every fixed time period, compares the data acquired in the current time period with the data acquired in the previous time period, determines the acquired data with inconsistent comparison results, and then sends only the data with inconsistent comparison results to the digital model in the virtual simulation software.
Further, in the seventh step, when the data acquisition system transmits the acquired data to the virtual simulation software, a timestamp and a data packet identifier are added to the transmitted data, wherein the data packet identifier is 0 initially, and is automatically added by one each time of transmission; when the virtual simulation software receives the collected data, comparing the difference between the currently received data packet identifier and the previously received data packet identifier, and if the difference between the currently received data packet identifier and the previously received data packet identifier is 1, performing data mapping and executing processing logic on the current data packet identifier; and if the difference between the currently received data packet identifier and the previously received data packet identifier is negative, discarding the currently received data.
The beneficial effects of the invention are as follows: the three-dimensional model and layout of each device of the production line are built by using the digital factory simulation software, so that the time and cost for building the layout of the production line from the bottom layer are greatly reduced; the decoupling of modeling and layout personnel and data acquisition system developers is realized, the requirements of the production line three-dimensional monitoring system developers are reduced, and the development period is shortened; the production process can be simulated and optimized in the virtual space before actual production, potential problems can be found before production, and the production efficiency of a production line is improved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, and are not to be considered limiting of the invention, in which:
fig. 1 is a general scheme of the present invention.
Fig. 2 is a demonstration of the operation of the Dobot robot three-dimensional monitoring system.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, which shows a general scheme of the method for implementing a three-dimensional factory monitoring system based on virtual simulation according to the present invention, the method mainly uses digital factory simulation software to build a production line layout and call Python API provided by the simulation software to develop a communication module between the production line layout and an external program, and maps data acquired by a data acquisition system onto each equipment model of the production line to implement three-dimensional dynamic monitoring of field production conditions, and the specific method comprises the following steps:
the method comprises the following steps: digital plant simulation software Visual Components are used for establishing a digital model of actual physical equipment, corresponding nodes are established according to the action condition of the equipment, and corresponding attributes and behaviors are added.
For example, there is a Dobot robot in an actual production line, if a digital model of the Dobot robot is to be built, the Dobot robot model built in three-dimensional software needs to be imported into Visual Components software, since the Dobot robot has four axes capable of rotating, and 2 axes and 3 axes drive to adopt a link mechanism, corresponding nodes are built according to moving parts and corresponding kinematic relationships are added, and since there are four degrees of freedom, the robot needs to be added to control the behavior of the four axes and control the rotation of each axis. According to the limiting and moving speed and acceleration parameters of each axis of the actual Dobot robot, the limiting and moving speed and acceleration parameters are consistent in the simulation model, namely the limiting and moving speed and acceleration parameters in the simulation model in Components software are consistent with the limiting and moving speed and acceleration parameters of each axis of the actual Dobot robot.
Step two: and acquiring data which can be openly acquired by the actual physical equipment, and developing a data acquisition system according to a communication interface and a protocol of the actual physical equipment.
Step three: adding corresponding attributes and behaviors to a digital model established in Visual Components of digital plant simulation software according to the data of the actual equipment which can be acquired in the step two;
for example, the Dobot robot described in the first step needs to add attributes such as angular displacement, angular velocity, and angular acceleration of each joint, and needs to add behaviors such as an actuator and a Python script.
Step four: defining a data mapping mode of a digital model established in a data acquisition system and digital factory simulation software Visual Components, adopting a TCP/IP protocol, adding a communication module for communicating with the digital model in the data acquisition system, and sending acquired data to the digital model;
step five: establishing a one-to-one mapping relation between data acquired in the data acquisition system and data contained in the digital model, calling a Python API development communication module provided by Visual Components software, and receiving the acquired data, namely mapping the data acquired in the data acquisition system into the data in the digital model;
step six: adding a PythonScript behavior in the digital model, and defining corresponding processing logic of the digital model after receiving data in the PythonScript;
the processing logic implements a simulation of the device by performing behaviors or attributes on the digital model that are consistent with the data collected.
For example, when the actual Dobot robot 1 axis rotates, the data acquisition system acquires that the angular displacement of the 1 axis changes, and accordingly, it needs to define that the angular displacement of the Dobot model 1 axis is equal to the angular displacement of the 1 axis acquired by the acquisition system in the Python script, and control the robot to move to a corresponding position.
Step seven: and (4) operating a data acquisition system to acquire data in the physical equipment, connecting the data acquisition software in the simulation environment of the digital plant simulation software Visual Components, operating the simulation environment, transmitting the acquired data to the digital plant simulation software Visual Components in real time by the data acquisition system, receiving the acquired data in real time in the digital plant simulation software Visual Components, mapping the received acquired data into data in the digital model according to the mapping relation established in the fifth step, and processing the digital model correspondingly by using corresponding processing logic defined in the PythonScript behavior established in the sixth step after receiving the data, so that the field equipment monitoring is realized, and the actual monitoring demonstration is shown as figure 2.
The invention uses the simulation software of the digital factory to set up the layout of the production line and call the Python API provided by the simulation software to develop the communication module between the simulation software and the external program, and maps the data acquired by the data acquisition system to each equipment model of the production line, thereby realizing the three-dimensional dynamic monitoring of the field production condition, on one hand, the production condition of the production line can be visually monitored, and the fault of the production equipment can be found in time; on the other hand, the modeling time for building the layout of the production line from the bottom layer is greatly reduced, and the development period of the three-dimensional monitoring system is shortened; in addition, the simulation and optimization of the production process can be carried out in the virtual space before actual production, potential problems can be found before production, and the production efficiency of a production line is improved.
Further, in the seventh step, when the data acquisition system transmits the acquired data to the virtual simulation software, because the data acquisition system usually transmits and receives the data in real time, in order to avoid the jamming of monitoring or reduce the transmission amount, the transmission mode uses an incremental transmission mode, that is, the data acquisition system acquires data of the physical device at regular intervals, compares the data acquired in the current time period with the data acquired in the previous time period, determines the acquired data with inconsistent comparison results, and then transmits only the data with inconsistent comparison results to the digital model in the simulation software.
Further, in the seventh step, in order to solve the real-time sending and receiving efficiency, a time stamp and a data packet identifier are added when sending data, wherein the data packet identifier is initially 0, and is automatically added by one each time of sending; when a receiving module in the simulation software receives an acquired data packet, comparing the difference between the identifier of the currently received data packet and the identifier of the previously received data packet, and if the difference between the identifier of the currently received data packet and the identifier of the previously received data packet is 1, performing data mapping and executing processing logic on the identifier of the currently received data packet; if the difference between the currently received data packet identifier and the previously received data packet identifier is a negative number, which indicates that the currently received data packet is expired and does not need to be processed again, the currently received data packet is discarded.
The above examples are only intended to illustrate the technical solution of the present invention, and not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (9)
1. A method for realizing a three-dimensional factory monitoring system based on virtual simulation is characterized by comprising the following steps:
the method comprises the following steps: establishing a digital model of actual physical equipment by using digital factory simulation software Visual Components, establishing corresponding nodes according to the action condition of the equipment, and adding corresponding attributes and behaviors;
step two: acquiring data which can be openly acquired by actual physical equipment, and developing a data acquisition system according to a communication interface and a protocol of the actual physical equipment;
step three: adding corresponding attributes and behaviors to a digital model established in Visual Components of digital plant simulation software according to the acquired data of the actual physical equipment;
step four: defining a data mapping mode of a data acquisition system and a digital model, adopting a TCP/IP protocol, adding a module which is communicated with a virtual simulation digital model in the data acquisition system, and sending acquired data to the virtual simulation digital model;
step five: calling a Python API development communication module provided by Visual Components software according to a data mapping mode of a data acquisition system and a virtual simulation digital model, and receiving acquired data;
step six: adding a PythonScript behavior in the virtual simulation digital model component, and defining corresponding processing logic of the virtual simulation digital model component after receiving data in the PythonScript behavior;
step seven: and operating the data acquisition system to acquire data in the physical equipment, connecting the data acquisition software in the simulation environment of the digital plant simulation software Visual Components, operating the simulation environment, transmitting the acquired data to the digital plant simulation software Visual Components in real time by the data acquisition system, receiving the acquired data in real time by the digital plant simulation software Visual Components, mapping the received acquired data into data in the digital model according to the mapping relation established in the fifth step, and correspondingly processing the digital model by using corresponding processing logic defined in the PythonScript behavior established in the sixth step after the data is received, so as to realize field equipment monitoring.
2. The method of claim 1, wherein step one further comprises:
the used virtual simulation software is Visual Components software, and the process of establishing a specific digital model comprises the following steps: if the virtual simulation software Visual Components self-contained library contains the model of the actual physical equipment, detecting whether the sizes and the behaviors are matched with the actual physical equipment, if not, carrying out corresponding modification, if the virtual simulation software Visual Components self-contained library does not contain the model of the actual physical equipment, firstly establishing a three-dimensional model of the equipment in the three-dimensional modeling software, and then importing the three-dimensional model into the virtual simulation software Visual Components to define corresponding nodes, attributes and behaviors.
3. The method of claim 1, wherein the data acquisition system in step two is developed under Winform framework in VS2015 development environment using C # language, and the system not only has data acquisition function, but also has function of controlling field devices.
4. The method of claim 1, wherein the collected data is data that can be collected by a sensor installed in the field physical device, and includes displacement and velocity.
5. The method according to claim 1, wherein the attributes and behaviors added by the digital model in step three specifically include: a shaping data attribute, a floating point data attribute, a boolean data attribute, a character data attribute, a Controller behavior, a Container behavior, a Signal behavior, a pythoncript behavior, and the like.
6. The method according to claim 1, wherein in the sixth step, the processing logic of the simulation model component includes that when the collected information changes, the state of the simulation model is correspondingly changed, including the action information and the state information of each model, so as to realize the one-to-one mapping between the collected data and the digital model data.
7. The method of claim 1, wherein the data acquisition system is connected to the virtual simulation software via wireless or wired communication.
8. The method according to claim 1, wherein in the seventh step, when the data acquisition system sends the acquired data to the virtual simulation software, the data acquisition system performs data acquisition on the physical device at regular intervals, compares the data acquired in the current time period with the data acquired in the previous time period, determines the acquired data with inconsistent comparison results, and then sends only the data with inconsistent comparison results to the digital model in the virtual simulation software.
9. The method according to claim 1, wherein in the seventh step, when the data acquisition system sends the acquired data to the virtual simulation software, a timestamp and a data packet identifier are added to the sent data, wherein the data packet identifier is initially 0, and is automatically added by one each time the data packet identifier is sent; when the virtual simulation software receives the collected data, comparing the difference between the currently received data packet identifier and the previously received data packet identifier, and if the difference between the currently received data packet identifier and the previously received data packet identifier is 1, performing data mapping and executing processing logic on the current data packet identifier; and if the difference between the currently received data packet identifier and the previously received data packet identifier is negative, discarding the currently received data.
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| DE102019204480A1 (en) * | 2019-03-29 | 2020-10-01 | Siemens Aktiengesellschaft | Method for engineering an automation system for controlling a process in a technical installation and automation system |
| CN111857063A (en) * | 2019-04-29 | 2020-10-30 | 西门子股份公司 | Method, device and system for acquiring digital data of factory |
| CN110320873A (en) * | 2019-07-05 | 2019-10-11 | 武汉魅客科技有限公司 | A kind of real-time three-dimensional presentation system based on distributed sensor |
| CN110598280B (en) * | 2019-08-28 | 2023-06-16 | 杭州友电科技有限公司 | Equipment simulation system and method and computer readable storage medium |
| CN110658795B (en) * | 2019-10-10 | 2020-07-31 | 北京航空航天大学 | Accurate fusion method and system for digital twin data |
| CN111324045B (en) * | 2019-10-31 | 2023-11-17 | 武汉数字化设计与制造创新中心有限公司 | Production line simulation system and method combining simulation and real objects |
| CN113009885A (en) * | 2019-12-20 | 2021-06-22 | 中国科学院沈阳计算技术研究所有限公司 | Digital mapping system and method for safety state of numerical control system |
| CN111062150A (en) * | 2019-12-25 | 2020-04-24 | 北京达美盛软件股份有限公司 | Three-dimensional visual factory management system |
| CN111308975A (en) * | 2020-02-28 | 2020-06-19 | 南京航空航天大学 | Twin agent construction system and method of intelligent manufacturing system based on digital twin technology |
| CN111368443A (en) * | 2020-03-06 | 2020-07-03 | 北京旷视机器人技术有限公司 | Equipment simulation method and device and electronic equipment |
| CN111638689B (en) * | 2020-05-15 | 2022-03-22 | 连云港杰瑞自动化有限公司 | Production line data centralized acquisition and control system and method based on automatic master control system |
| CN112114529A (en) * | 2020-07-30 | 2020-12-22 | 浙江工业大学 | Simulation debugging system for hardware industry |
| CN112418455B (en) * | 2020-11-28 | 2021-07-20 | 北京三维天地科技股份有限公司 | Equipment failure prediction and health management system |
| CN112632778B (en) * | 2020-12-22 | 2023-07-18 | 达闼机器人股份有限公司 | Operation method and device of digital twin model and electronic equipment |
| CN115473943A (en) * | 2022-08-15 | 2022-12-13 | 西门子（中国）有限公司 | Interface extension method, extension interface using method, system and storage medium |
| CN115756472B (en) * | 2023-01-06 | 2023-05-09 | 江苏中车数字科技有限公司 | Cloud-edge cooperative industrial equipment digital twin operation monitoring method and system |
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| CN107870600B (en) * | 2017-10-17 | 2018-10-19 | 广东工业大学 | A kind of transparent monitoring method in intelligence workshop and system |
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