CN109947052B - Virtual factory manufacturing execution system and method based on digital AR technology - Google Patents
Virtual factory manufacturing execution system and method based on digital AR technology Download PDFInfo
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- CN109947052B CN109947052B CN201711381393.5A CN201711381393A CN109947052B CN 109947052 B CN109947052 B CN 109947052B CN 201711381393 A CN201711381393 A CN 201711381393A CN 109947052 B CN109947052 B CN 109947052B
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Abstract
The invention discloses a virtual factory manufacturing execution system based on a digital AR technology. The system adopts a digital Augmented Reality (AR) technology and a data acquisition technology, and dynamically reproduces a production scene by controlling the real-time transmission of system signals. Through proper file configuration and a small amount of programming, the system can make visual reaction and feedback processing consistent with real scenes on real-time events of human, machine, material, law and loop five links in an industrial field at the first time. No matter where the user is positioned, the user can look like the factory condition just like the field by only needing to pass through the network equipment, so that the work instruction in the factory is issued, the remote visual monitoring is realized, and the purposes of mastering, guiding and controlling the production process are achieved.
Description
Technical Field
The invention relates to visual monitoring and management of a real factory, in particular to a virtual factory manufacturing execution system based on a digital AR technology.
Background
At present, for a manufacturing execution system of a factory, a common manufacturing execution system mostly adopts a 2D picture and text description mode to manage a production workshop, and a manufacturer can see the appearance of a production line and the assembly mode of parts on the picture and understand the functions and the production sequence of various devices through pictures and texts. However, this approach is not intuitive and it is difficult for untrained personnel to understand the method of use of a particular type of equipment or tool simply by graphical illustration. Meanwhile, in the daily production process, when a factory occurs an event, a common manufacturing execution system is difficult to quickly and accurately position the fault position of equipment, so that the fault cannot be timely eliminated. These all invisibly reduce the production efficiency of the enterprise, increase the overhead and cost of the enterprise.
With the virtual factory manufacturing execution system, different scenes can be set to adjust the production line in advance, the most efficient solution is found, and the passive plan is changed into the active plan adjustment. The operation data of the physical factory is mapped to the virtual factory, so that the virtual factory is driven to operate, and workers can comprehensively control factory events such as logistics transportation progress, production assembly progress and equipment operation state in the factory only by facing the dynamic three-dimensional model of the virtual factory.
Disclosure of Invention
Aiming at the monitoring and management requirements of the existing manufacturing execution system, the invention provides a virtual factory manufacturing execution system based on a digital AR technology.
The technical scheme adopted by the invention for realizing the purpose is as follows: a virtual factory manufacturing execution system based on digital AR technology comprises a process control module, a communication interface module and a virtual enhancement module;
the process control module is used for driving the field equipment to act and collecting the motion state of the field equipment;
the communication interface module is used for realizing the communication between the process control module and the virtual enhancement module;
and the virtual enhancement module is used for constructing a virtual factory scene and displaying the action of the field equipment in real time according to the motion state of the field equipment.
The process control module comprises a PLC, an AGV, a production line conveyor belt, an RFID, a sensor and a wireless PDA; the field device comprises a PLC, an AGV and a production line conveyor belt.
The communication interface module comprises an OPC-UA interface, a WebSocket interface and an AJAX interface.
The virtual enhancement module comprises a visual process monitoring module, a production order tracking module, a scene modeling module, an equipment element modeling module, a 3D graphic engine and a platform architecture service module;
the scene modeling module is used for scanning the surface of the workshop field equipment to obtain the three-dimensional coordinates of the field equipment, and constructing a field equipment model according to the three-dimensional coordinates to realize scene modeling;
the device element modeling module is used for associating the motion state data with the field device model according to the motion state data acquired by the process control module, namely converting the motion state data of the field device into a motion track of the field device model corresponding to the motion state data;
a production order tracking module for selecting field devices according to a production plan;
the visual process monitoring module is used for acquiring and displaying production task information;
and the 3D graphic engine and the platform architecture service module are used for carrying out 3D dynamic display on the selected field device model according to the motion state data.
A virtual factory manufacturing execution method based on digital AR technology comprises the following steps;
the process control module drives the field device to act and collects the motion state of the field device;
the communication interface module realizes the communication between the process control module and the virtual enhancement module;
the virtual enhancement module constructs a virtual factory scene and displays the actions of the field equipment in real time according to the motion state of the field equipment.
The virtual augmentation module performs the following steps;
the scene modeling module scans the surface of the workshop field device to obtain the three-dimensional coordinates of the field device, and constructs a field device model according to the three-dimensional coordinates to realize scene modeling;
the device element modeling module associates the motion state data with the field device model according to the motion state data acquired by the process control module, namely the motion state data of the field device is converted into a motion track of the field device model corresponding to the motion state data;
the production order tracking module selects field equipment according to a production plan;
the visual process monitoring module acquires and displays production task information;
and the 3D graphic engine and the platform architecture service module perform 3D dynamic display on the selected field device model according to the motion state data.
The invention has the following beneficial effects and advantages:
1. the method has the advantages that a common manufacturing execution system is abandoned, production workshops are managed by means of 2D pictures and word descriptions, the factory is enhanced in a virtual mode, 3D modeling is adopted, and factory scenes are displayed more intuitively and conveniently;
2. the system can enable personnel to quickly know the structure, the function, the running state and the process flow of the equipment of the factory, shorten the training and learning time of the personnel and reduce the expenditure of enterprises;
3. in the daily production process and when a factory event occurs, the virtual factory can rapidly and accurately position the factory event location and the factory event description by using the dynamic 3D model motion change, thereby improving the factory production efficiency and the assembly quality and improving the enterprise profit;
4. the virtual factory manufacturing execution system accords with the development direction of combining industrial 4.0 and future artificial intelligence technology with AR technology and cloud data technology, and facilitates the upgrading and expansion of systems in the future.
Drawings
FIG. 1 is a block diagram of a virtual fab execution system according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
As shown in fig. 1, the present invention comprises 4 functional modules, which are respectively a process control module, a communication interface module, a virtual enhancement module, and a manufacturing execution module from bottom to top.
The process control module is a source of plant data, and mainly depends on a sensing network technology and PLC logic control to realize the logic action of equipment and provide automatic plant process data. And the factory equipment internet of things is realized by adopting various industrial bus technologies such as ProfiNet, industrial Ethernet and the like.
The communication interface module is a data carrier and continuously transfers the production data provided by the process control module to the virtual enhancement module and the manufacturing execution module. The animated dynamic effect of the virtual plant model presented to the user can be achieved.
The equipment communication interface adopts an OPC-UA mode and a third party manufacturer SDK mode to realize bidirectional communication, an OPC server is erected, and all factory equipment conforming to OPC specifications is supported; the manufacturing execution system interface adopts a WebService, a WebAPI and an internal function processing method to realize data bidirectional communication, and data monitoring, statistics and analysis; the AR virtual factory interface adopts a B/S architecture, sends a virtual factory request to a server in an AJAX asynchronous communication mode through network equipment and a browser, and manufactures an execution system processing result and responds to the browser request. Meanwhile, the server actively pushes factory events for each subscribed virtual factory in a WebSocket mode.
The virtual enhancement module is used for displaying visual dynamic virtual works, and the virtual factory modeling adopts a three-dimensional laser scanning technology, so that the spatial sampling Point-Point Cloud (Point Cloud) data containing three-dimensional coordinates of the surface of a real object can be directly obtained. The engineer installs the laser scanning gun on the support that can 360 degrees rotations in advance, then settles in the factory building. The device can complete one scan in 3 minutes, the scanning range is nearly 100 square meters, and 2000 ten thousand spatial sampling points are generated. The scanning device is then moved to the next location and scanning continues to produce a new point cloud. All the point clouds are combined together in a computer to gradually build a virtual factory, and the accuracy error is between 1 mm and 3 mm compared with a real factory.
The visualized process monitoring of the virtual enhancement module is a window displayed to a user by the system, and displayed data is acquired from process information, logistics information, quality data, equipment data and personnel data in the manufacturing execution module through a WebService technology. Such as process files, material BOM, quality detection results, quality real-time online SPC, equipment alarm, equipment maintenance, equipment point inspection, personnel attendance, personnel performance, personnel skills and the like.
The production order tracking of the virtual enhancement module is condensed and summarized from the production plan of the manufacturing execution module through the WebService technology. And then, through ajax and websocket technologies, bidirectional transmission and display are carried out between the visualization process monitoring and the background.
The scene modeling of the virtual enhancement module is to rapidly reconstruct a three-dimensional coarse-grained model of workshop equipment and various drawing data such as lines, surfaces and volumes by recording information such as three-dimensional coordinates, reflectivity and textures of a large number of dense points on the surface of the workshop equipment by utilizing a laser ranging principle. The scanning range of the whole production line full coverage is realized through technical means such as splicing. The observed and obtained effects are achieved. And finally, finishing scene modeling through the fine data.
The equipment element modeling of the virtual enhancement module is to acquire the data of the bottom process control module through opc, sdk and other means and to associate the data with the scene model. If the travel distance of the wire body tray is converted into the motion coordinate, the rotating head of the tightening machine is converted into an angle.
The 3D graphic engine and the platform architecture service of the virtual enhancement module adopt an open-source cross-platform 3D application development framework Minko, and a Minko core framework has a highly extensible and documentable editor. The method integrates a physical engine, creates an interactive script by utilizing Minko Studio, combines file data after three-dimensional laser point cloud modeling with a front-end development language, and realizes design and development of 3D application of a web platform by utilizing HTML 5.
The virtual factory of this embodiment includes intelligent work or material rest, multiple industrial robot, AGV commodity circulation transport vechicle, work piece, anchor clamps, tray, conveyer belt etc. of a production line, line limit storehouse.
Based on the established virtual digital workshop model base and animation base, the instruction base defines the mapping relation between the production instruction and the model by defining the mapping relation between the model, the animation attribute and the moving part and the model, and the data exchange plug-in completes the data mapping between the real-time data and the three-dimensional simulation platform. And sending a real-time instruction to the three-dimensional simulation platform according to condition triggering, analyzing the production instruction by the three-dimensional simulation platform, and driving the change of the model matrix to realize the motion of the three-dimensional model. Including physical characteristics such as position changes, rotation, impact, telescoping, hand grasping, surface deformation in a factory scene. Through complex modeling, the virtual factory can truly simulate various factory devices and the automatic production line of logic control.
The invention can clearly see the travel track of the AGV logistics transport vehicle, the assembly action of the robot, the conveying flow of the tray on the conveying belt, the alarm prompt of the equipment, the assembly process of the product, the material state information of the intelligent material rack of the line side warehouse and the like in a virtual factory.
By observing, knowing and learning the plant structure and the physical action and characteristics of the equipment in the virtual plant manufacturing execution system, the danger and damage caused by unfamiliarity with the equipment can be avoided for a user on a real production field, and the user can enter a plant role more quickly to bear the plant task. Meanwhile, in the daily production and assembly process, the production state is rapidly known, production events are positioned, production faults are solved, the enterprise productivity is improved, and the enterprise cost is reduced.
The manufacturing execution module is part of the production line MES system and is prior art. The invention obtains information such as production plans, production tasks and the like from the module, can quickly react and process events in a factory, and carries out a real-time display process on the processing result through a virtual factory.
The manufacturing execution system comprises six functions: production plan management, process information management, logistics information management, quality data management, personnel information management and equipment information management.
The main functions of production plan management include: APS advanced scheduling, production order receiving and issuing, production bar code printing and setting and the like;
the main functions of quality data management include: online SPC statistical analysis, product quality tracing, product archives and the like;
the main functions of device data management include: equipment alarm information, equipment maintenance and repair and the like;
the main functions of personnel information management include: authority setting, role distribution, personnel attendance and the like;
the main functions of material information management include: material auditing, material forward/backward tracing and the like;
the main functions of process information management include: and assembling BOM, operation instruction book and inputting and inquiring process cards.
Claims (3)
1. A virtual factory manufacturing execution system based on digital AR technology is characterized by comprising a process control module, a communication interface module and a virtual enhancement module;
the process control module is used for driving the field equipment to act and collecting the motion state of the field equipment;
the communication interface module is used for realizing the communication between the process control module and the virtual enhancement module;
the virtual enhancement module is used for constructing a virtual factory scene and displaying the action of the field equipment in real time according to the motion state of the field equipment;
the communication interface module comprises an OPC-UA interface, a WebSocket interface and an AJAX interface;
the virtual enhancement module comprises a visual process monitoring module, a production order tracking module, a scene modeling module, an equipment element modeling module, a 3D graphic engine and a platform architecture service module;
the scene modeling module is used for scanning the surface of the workshop field equipment to obtain the three-dimensional coordinates of the field equipment, and constructing a field equipment model according to the three-dimensional coordinates to realize scene modeling;
the device element modeling module is used for associating the motion state data with the field device model according to the motion state data acquired by the process control module, namely converting the motion state data of the field device into a motion track of the field device model corresponding to the motion state data;
a production order tracking module for selecting field devices according to a production plan;
the visual process monitoring module is used for acquiring and displaying production task information;
and the 3D graphic engine and the platform architecture service module are used for carrying out 3D dynamic display on the selected field device model according to the motion state data.
2. The virtual factory manufacturing execution system based on digital AR technology of claim 1, wherein said process control modules comprise PLC, AGV, production line conveyor, RFID, sensor, wireless PDA; the field device comprises a PLC, an AGV and a production line conveyor belt.
3. The method for implementing a virtual factory manufacturing system based on digital AR technology as claimed in claim 1, comprising the steps of;
the process control module drives the field device to act and collects the motion state of the field device;
the communication interface module realizes the communication between the process control module and the virtual enhancement module;
the virtual enhancement module constructs a virtual factory scene and displays the actions of the field equipment in real time according to the motion state of the field equipment;
the virtual augmentation module performs the following steps;
the scene modeling module scans the surface of the workshop field device to obtain the three-dimensional coordinates of the field device, and constructs a field device model according to the three-dimensional coordinates to realize scene modeling;
the device element modeling module associates the motion state data with the field device model according to the motion state data acquired by the process control module, namely the motion state data of the field device is converted into a motion track of the field device model corresponding to the motion state data;
based on the established virtual digital workshop model library and animation library, the instruction library defines the mapping relation between the production instruction and the model by defining the mapping relation between the model, the animation attribute and the moving part and the model, and the data exchange plug-in completes the data mapping between the real-time data and the three-dimensional simulation platform;
sending a real-time instruction to a three-dimensional simulation platform according to condition triggering, analyzing a production instruction by the three-dimensional simulation platform, and driving the change of a model matrix to realize the motion of a three-dimensional model;
movement of the three-dimensional model, comprising: the physical characteristics of position change, rotation, collision, expansion, hand grasping and surface deformation in a factory scene enable a virtual factory to truly simulate various factory devices and logically controlled automatic production lines;
the production order tracking module selects field equipment according to a production plan;
the visual process monitoring module acquires and displays production task information;
and the 3D graphic engine and the platform architecture service module perform 3D dynamic display on the selected field device model according to the motion state data.
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| CN110751431B (en) * | 2019-09-18 | 2024-02-06 | 国机工业互联网研究院(河南)有限公司 | Material tracking method and system based on track carrier |
| CN110716501A (en) * | 2019-11-18 | 2020-01-21 | 康美包（苏州）有限公司 | Data transmission method, equipment and device and computer storage medium |
| CN111127657B (en) * | 2019-11-29 | 2023-06-20 | 重庆顺泰铁塔制造有限公司 | Virtual manufacturing method and system based on Unreal Engine |
| CN111770450B (en) * | 2020-05-22 | 2022-02-18 | 同济大学 | Workshop production monitoring server, mobile terminal and application |
| CN112114567A (en) * | 2020-08-06 | 2020-12-22 | 江苏天和信息技术有限公司 | Information management system and method for casting unit |
| CN112859768A (en) * | 2020-12-31 | 2021-05-28 | 合肥科博软件技术有限公司 | Three-dimensional dynamic state monitoring method and system for production line |
| CN113744618A (en) * | 2021-09-17 | 2021-12-03 | 南京东道电子装备技术研究院有限公司 | Sand table type intelligent factory simulation demonstration system |
| CN114063512B (en) * | 2021-11-15 | 2023-09-19 | 中国联合网络通信集团有限公司 | Maintenance service guiding and monitoring method, cloud platform, AR glasses and system |
| CN115034525B (en) * | 2022-08-11 | 2022-11-22 | 宝信软件(南京)有限公司 | Steel pipe order production period prediction monitoring system and method based on data analysis |
| CN115410354B (en) * | 2022-08-31 | 2023-11-14 | 国能神东煤炭集团有限责任公司 | Safety early warning method and device and safety early warning system for industrial factory |
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