CN111708332B - Digital twin system of production line - Google Patents
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41805—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by assembly
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41815—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the cooperation between machine tools, manipulators and conveyor or other workpiece supply system, workcell
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
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- G05B19/41835—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by programme execution
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
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- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G—PHYSICS
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- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
- G05B19/4186—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication by protocol, e.g. MAP, TOP
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- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G—PHYSICS
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- G05B19/4188—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by CIM planning or realisation
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a production line digital twin system, which instantiates and creates a digital twin production line through an industrial information model module, and compiles a communication and motion control program based on a Unity3D physical engine to construct a production line twin system man-machine interaction module; the data acquisition module acquires and analyzes actual state data of the production line in real time, writes a communication program based on an MQTT protocol to realize data synchronization of the twin system and the physical production line, manages the state data of the production line and forwards the state data to the production line performance evaluation module; the production line performance evaluation module calculates the performance index of the production line in real time by analyzing the production line operation data; the production line control service module is used for controlling workshop production line equipment by issuing numerical control instructions to the equipment in the system. The invention simplifies the simulation process of the production line manufacturing execution process, improves the design efficiency of the production line simulation system and improves the workshop production integration management level.
Description
Technical Field
The invention relates to the technical field of intelligent manufacturing, in particular to a digital twinning system of a production line.
Background
The digital twin is to create a virtual model of a physical entity in a digital mode, simulate the behavior of the physical entity in a real environment by means of data, and add or expand new capability to the physical entity through means of virtual-real interaction feedback, data fusion analysis, decision iteration optimization and the like. For the field of manufacturing, a digital twin may also be defined as "a dynamic model that digitally describes manufacturing elements such as people, products, equipment, and processes and is updated synchronously as objects exhibit changes in state, operating conditions, product geometry, and resource status," which provides the dynamic nature of the operation of the elements and physical world "objects" and exists throughout the life cycle of the objects.
The simulation aiming at the manufacturing execution process of a workshop production line is a complex process, and the processes of the layout, the production manufacturing process path, the logistics scheme and the like of the production line can be virtually simulated by some three-dimensional simulation software at present, but the virtual simulation is based on theoretical data in the design process, the effective utilization of actual data is lacked, and the obtained simulation result has certain deviation from the actual result. Aiming at the monitoring aspect of the production process of the production line, the production pictures of the production line are subjected to video recording and storage by installing a monitoring camera at present, so that the real-time monitoring of the production process of the production line can be realized, the technical difficulty of installation and deployment is lower, but the used cost is more, the storage volume is large, the management difficulty is high, and the maintenance cost is high.
Disclosure of Invention
The technical problem solved by the invention is as follows: the defects of the prior art are overcome, the production line digital twin system is provided, the virtual-real interaction function of a production line entity and a production line twin body is realized by taking production line actual data as a basis, the problems of real-time dynamic simulation, virtual monitoring, analysis and evaluation and the like of a production line execution manufacturing process are solved, and the integrated and visual management level of a workshop production line is improved.
The technical scheme of the invention is as follows: a production line digital twinning system, the system comprising: the system comprises a real-time data acquisition module, an industrial information model module, a man-machine interaction module, a production line performance evaluation module and a production line control service module; wherein:
the real-time data acquisition module is used for receiving production state data acquired by an actual production line in real time and forwarding the production state data to the man-machine interaction module and the production line performance evaluation module;
the industrial information model module is used for constructing, storing and managing information models of components related in an actual production line, and the information models comprise a geometric model, a physical information model, a functional information model and a performance information model;
the human-computer interaction module is used for receiving the production line state data sent by the real-time data acquisition module and decomposing the production state data of the actual production line to obtain the actual production state data of each part related to the actual production line; establishing a virtual production line corresponding to the actual production line, namely: the digital twin production line is realized by instantiating a geometric model corresponding to a related component in an actual production line in an industrial information model module, the geometric model binds a physical information model, a functional information model, a performance information model and a motion control display program of the component in the form of attributes, the motion control display program of each component extracts actual production state data corresponding to the component, interpolation processing is carried out on the actual production state data corresponding to the component to obtain virtual production state data, the geometric model is controlled to move, rotate and change to complete simulation actions according to the virtual production state data to realize dynamic simulation of the production process of the production line, and meanwhile, the production state data corresponding to the component is visually expressed on an interface in the form of a chart;
the production line performance evaluation module is used for receiving the production state data sent by the real-time data acquisition module, taking the data as input data, automatically calculating and displaying each single index value by using each single performance index calculation method of the actual production line, and performing overall evaluation on the comprehensive performance of the actual production line according to each single index value;
and the production line control service module receives an externally input equipment control instruction, issues the equipment control instruction to corresponding equipment in the actual production line, and controls the working state of the equipment.
The production state data comprises equipment state, personnel state, product state, logistics state and energy state data;
the device status data includes: equipment running time, single-procedure processing time and equipment on-off state;
the personnel status includes: personnel real-time position, personnel working time, personnel number and personnel job number;
the product state comprises: the number of products in process, the type of products in process, the number of products in process and the daily output of various products;
the logistics state comprises the following steps: the real-time position of a product being processed, the real-time position of logistics equipment, the working time of the logistics equipment, the standby time of the logistics equipment, the warehousing time of each batch of products, the quantity of warehoused products in each batch, the ex-warehouse time of each batch of products, the quantity of ex-warehouse products in each batch and the quantity of real-time warehouse locations;
the energy state information comprises: workshop electric meter data, cooling liquid usage, and lubricating liquid usage.
The real-time data acquisition module comprises three parts of data acquisition, data management and data communication, wherein the data acquisition part acquires production state data in a workshop production line and sends the production state data to the data management part; the data management part backs up, encapsulates and stores the acquired state data; the data communication part is used as a data server, provides message publishing service for the man-machine interaction module used as a data subscription client according to a message queue telemetry transmission protocol, and sends the data encapsulated in the data management part to the man-machine interaction module, so that the digital communication between the production line site and the digital twin system is realized.
The industrial information model module further comprises a rule information model, wherein the rule information model comprises a production line balance principle and a substitution principle and is used for standardizing the adjustment flow of the production line and ensuring the reasonability of the production line in the adjustment process.
For equipment, the physical information model comprises linkage relation information of physical materials, volume, weight and motion mechanisms; the function information model comprises the function, the use, the brand and the in-service time information of the equipment; the performance information model comprises the production capacity, the maximum load, the rotating speed, the precision, the cooling time, the calibration time, the maintenance period and the equipment failure rate information of the equipment;
for a person, the physical information model comprises a skeleton model and a joint action state of the person; the functional information model comprises personnel functions, operation skills and management authority information; the performance information model comprises age, working age, proficiency, work efficiency and work cycle information;
for the material, the physical information model comprises material attribute, appearance color, volume and weight information of the material; the functional information model comprises material serial number, material usage and processing requirement information; the performance information model comprises processing procedure and warehouse-in and warehouse-out inspection requirement information;
for a product, the physical information model comprises material attribute, appearance color, volume and weight information; the function information model comprises product use, model and number information; the performance information model comprises assembly precision and performance parameter information.
The motion control display program comprises a motion simulation module and a process monitoring module;
the motion simulation module periodically extracts actual production state data of the corresponding component, performs interpolation processing on the actual production state data based on the kinematics principle of the component to obtain virtual production state data, and sends the virtual production state data to the process monitoring module;
and the process monitoring module simulates the real-time state of the corresponding part of the actual production line according to the virtual production state data and displays the real-time state on a screen to realize the virtual monitoring of the real-time production process of the production line.
The production line performance evaluation module comprises three parts of data processing, index calculation and comprehensive evaluation, wherein the data processing part receives and processes actual production line production state data sent by the real-time data acquisition module and sends the data to the index calculation part; the index calculation part integrates a calculation method of a plurality of production line single performance indexes, receives input data sent by the data processing part, automatically substitutes the input data into the data to calculate and display a calculation result, and forwards the single performance index result to the comprehensive evaluation part; and a performance evaluation module of the comprehensive evaluation part takes the calculation results of the single performance indexes as input according to a preset evaluation standard, adopts a hierarchical analysis method to obtain a comprehensive performance evaluation score, and performs overall evaluation on the comprehensive performance of the production line.
The production line control service module comprises three parts of instruction receiving, instruction interpretation and instruction sending, wherein the instruction receiving part receives a numerical control program input from the outside and sends the numerical control program to the instruction interpretation part; the instruction interpretation part interprets a specific zone bit in the numerical control program instruction, judges a receiving object of the program and sends a judgment result to the instruction sending part; the instruction sending part sends the equipment control instruction to corresponding equipment in the actual production line through a data interface module in the data acquisition module to control the state of the equipment.
The digital twin production line is realized by a Unity 3D-based physical engine.
The human-computer interaction interface is constructed by adopting a WFP interface framework.
Compared with the prior art, the invention has the beneficial effects that:
(1) the invention realizes real-time dynamic simulation and virtual monitoring of the workshop production line production process by establishing the production line digital twin system consisting of the real-time data acquisition module, the industrial information model module, the man-machine interaction module, the production line performance evaluation module and the production line control service module.
(2) The man-machine interaction module carries out dynamic simulation and real-time data display in the virtual production line by utilizing the collected actual production line manufacturing process data, thereby not only ensuring the authenticity and the accuracy of a simulation result, but also achieving the effect of virtual monitoring, and being capable of reducing the arrangement cost of a monitoring system to a great extent on the premise of realizing the monitoring of the whole production process of the production line.
(3) The man-machine interaction module of the invention utilizes the rule information model, ensures the rationality of the production line in the adjustment process and improves the error-proofing capability of the production line during the optimization adjustment.
(4) The production line performance evaluation module evaluates the overall performance of the production line by integrating a calculation method of the number performance indexes of the production line and utilizing an index comprehensive evaluation method, simplifies the evaluation flow of the production line, objectively and efficiently reflects the overall level of the production line performance through visual data, and shortens the time of manual evaluation.
(5) The production line control service module utilizes the functions of equipment control instruction receiving, instruction interpretation and instruction sending, reduces manual instruction sending of a technician, simplifies the working process and improves the efficiency.
Drawings
FIG. 1 is a functional architecture of a production line digital twinning system;
FIG. 2 is a flow chart of the real-time data acquisition module.
Detailed Description
The invention is further illustrated by the following examples.
As shown in fig. 1, the present invention provides a production line digital twin system, which integrates five functional modules, which are respectively: the system comprises a real-time data acquisition module, an industrial information model module, a man-machine interaction module, a production line performance evaluation module and a production line control service module. The real-time data acquisition module is used for providing real-time production line operation data for the production line digital twin system; the industrial information model module is used for constructing, storing and managing information models of components related in the production line; the man-machine interaction module is used for carrying out dynamic simulation and virtual monitoring on the production process of the production line; the production line performance evaluation module provides comprehensive performance evaluation for the production line digital twin system; the production line control service module is used for receiving and issuing control instructions and controlling the state of workshop equipment.
Each section is described in detail below:
(1) real-time data acquisition module
As shown in fig. 2, the real-time data acquisition module receives production state data acquired in real time by an actual production line, and forwards the production state data to the human-computer interaction module and the production line performance evaluation module.
The real-time data acquisition module comprises three parts of data acquisition, data management and data communication, wherein the data acquisition part acquires production state data in a production line at a fixed frequency through an intelligent sensor and an industrial acquisition protocol in a workshop production line and sends the production state data to the data management part; the data management part backs up, encapsulates and stores the acquired state data; the data communication part is used as a data server, provides message publishing service for the man-machine interaction module used as a data subscription client according to a message queue telemetry transmission protocol, and sends the data encapsulated in the data management part to the man-machine interaction module, so that the digital communication between the production line site and the digital twin system is realized.
The production state data comprises equipment state, personnel state, product state, logistics state and energy state data;
the device status data includes: equipment running time, single-procedure processing time and equipment on-off state;
the personnel status includes: personnel real-time position, personnel working time, personnel number and personnel job number;
the product state comprises: the number of products in process, the type of products in process, the number of products in process and the daily output of various products;
the logistics state comprises the following steps: the real-time position of a product being processed, the real-time position of logistics equipment, the working time of the logistics equipment, the standby time of the logistics equipment, the warehousing time of each batch of products, the quantity of warehoused products in each batch, the ex-warehouse time of each batch of products, the quantity of ex-warehouse products in each batch and the quantity of real-time warehouse locations;
the energy state information comprises: workshop electric meter data, cooling liquid usage, and lubricating liquid usage.
(2) Industrial information model module
The industrial information model module is used for constructing, storing and managing a regular information model of an actual production line and information models of components involved in the actual production line, wherein the information models comprise a geometric model, a physical information model, a functional information model and a performance information model.
The parts involved in the production line comprise equipment, personnel, materials and products, and geometric models of the parts can be parameterized by three-dimensional design software and stored in a model file library in a common format, such as STP and IGS format.
For equipment, the physical information model comprises linkage relation information of physical materials, volume, weight and motion mechanisms; the function information model comprises the function, the use, the brand and the in-service time information of the equipment; for example, the functions of the machining device include turning, milling, inspection; the performance information model comprises the production capacity, the maximum load, the rotating speed, the precision, the cooling time, the calibration time, the maintenance period and the equipment fault rate information of the equipment, and the numerical control machine performance comprises the maximum load, the precision, the rated rotating speed of the main shaft, the maintenance period and the equipment fault rate.
For a person, the physical information model comprises a skeleton model and a joint action state of the person; the functional information model comprises personnel functions, operating skills and management authority information, for example, the personnel functions can comprise carrying, assembling and checking; the performance information model comprises age, working age, proficiency, work efficiency, work cycle information and maximum work duration, wherein the work cycle refers to a double-rest system or a single-rest system in one week and a one-shift system or a two-shift system in one day.
For the material, the physical information model comprises material attribute, appearance color, volume and weight information of the material; the functional information model comprises material serial number, material usage and processing requirement information; the performance information model comprises processing procedure and warehouse-in and warehouse-out inspection requirement information;
for a product, the physical information model comprises material attribute, appearance color, volume and weight information; the function information model comprises product use, model and number information; the performance information model comprises assembly precision and performance parameter information.
The rule information model is oriented to the whole production line, is used for standardizing the adjustment flow of the production line and ensuring the rationality of the production line in the adjustment process, and comprises a production line balance principle and an alternative principle.
Aiming at the condition that the components of the virtual production line system need to be increased, reduced or replaced again, the industrial information module automatically compares the function and performance information data of the components, calculates the resource balance of the production line after replacement, judges whether the replacement principle and the balance principle of production line adjustment are met or not, and gives a judgment result.
(3) Man-machine interaction module
The man-machine interaction module receives the production line state data sent by the real-time data acquisition module, and decomposes the production state data of the actual production line to obtain the actual production state data of each part related to the actual production line; establishing a virtual production line corresponding to the actual production line, namely: the digital twin production line is realized by instantiating a geometric model corresponding to a related component in an actual production line in an industrial information model module, the geometric model binds a physical information model, a functional information model, a performance information model and a motion control display program of the component in the form of attributes, the motion control display program of each component extracts actual production state data corresponding to the component, interpolation processing is carried out on the actual production state data corresponding to the component to obtain virtual production state data, the geometric model is controlled to move, rotate and change to complete simulation actions according to the virtual production state data to realize dynamic simulation of the production process of the production line, and meanwhile, the production state data corresponding to the component is visually expressed on an interface in the form of a chart.
Specifically, the motion control display program comprises a motion simulation module and a process monitoring module, wherein the motion simulation module periodically extracts actual production state data of a corresponding component, interpolates the actual production state data based on the kinematics principle of the component to obtain virtual production state data, and sends the virtual production state data to the process monitoring module; the process monitoring module simulates the real-time state of the corresponding part of the actual production line according to the virtual production state data and displays the real-time state on a screen to realize the data-driven dynamic simulation of the three-dimensional virtual production line.
The human-computer interaction module and the digital twin production line also comprise a production line adjusting module, if a user executes an adjusting task on the production line, firstly, a regular information model in an industrial information model module is utilized, functional information and performance information of parts before and after adjustment are compared, the adjusted production line resource balance condition is calculated, whether the alternative principle and the balance principle of production line adjustment are met is judged, and if the judgment result is feasible, the user can adjust the parts in the virtual production line in the human-computer interaction module, such as replacing equipment/personnel, adding or deleting equipment/personnel; and if the judgment result is not feasible, outputting the infeasible result and immediately ending the adjustment task.
The man-machine interaction module comprises a production line three-dimensional interaction module and a two-dimensional interaction module; constructing a three-dimensional virtual production line based on the three-dimensional model and the Unity3D physical engine; and constructing a human-computer interaction interface based on a WFP interface framework, wherein the motion control display program is a production line control script written based on C #.
(4) Production line performance evaluation module
The production line performance evaluation module receives the production state data sent by the real-time data acquisition module, takes the data as input data, respectively calculates and displays each single index value by using each single performance index calculation method of the actual production line, and finally carries out overall evaluation on the comprehensive performance of the actual production line according to each single index value.
The production line performance evaluation module comprises three parts of data processing, index calculation and comprehensive evaluation, wherein the data processing part receives and processes actual production line production state data sent by the real-time data acquisition module and sends the data to the index calculation part; the index calculation part integrates a calculation method of a plurality of production line single performance indexes, receives input data sent by the data processing part, automatically substitutes the input data into the data to calculate and display a calculation result, and forwards the single performance index result to the comprehensive evaluation part; and a performance evaluation module of the comprehensive evaluation part takes the calculation results of the single performance indexes as input according to a preset evaluation standard, adopts a hierarchical analysis method to obtain a comprehensive performance evaluation score and provides a comprehensive performance overall evaluation result of the production line.
The production line single performance indexes comprise a productivity index, a resource balance index, a fault prediction index, a logistics efficiency index and an energy consumption index. The productivity is the upper limit of the production of one production process, can be used as the standard for measuring one station, can also be used as the standard for measuring the whole production line, and can finish the productivity evaluation of the production line through theoretical estimation.
The productivity index comprises the daily maximum productivity of the production line, and the calculation method comprises the following steps:
production line daily maximum productivity ═ sigma (product type X daily yield of various products)
Σ (-) means that the quantities in brackets are summed over time in one day.
Resource balance is an index for evaluating utilization efficiency of equipment and personnel, and machine cost and labor cost of the whole production line can be influenced if the resource balance rate is not high. The calculation includes two aspects, namely the balance rate of the production line and the yield per unit time of a single person.
The resource balance index comprises the balance rate of a production line and the yield of a single person in unit time; wherein:
considering that most of the material flows of production line workshops are circulated according to batches, in order to obtain the takt time of a production line, namely the finishing time of continuously producing two similar products, the conversion is carried out by dividing the time difference of two continuous batches of the similar products by the number of the products.
The fault rate prediction is a theoretical method for supporting the preventive maintenance strategy of the production line, and the fault rate of the whole production line can be periodically estimated by adopting an adjustment factor method and considering state functions such as the fault rate of equipment and the like and the service life of the equipment based on the fault rate and the maintenance period of a single piece of equipment.
The failure prediction index is the failure rate of single equipment and the failure rate of a production line.
After the ith maintenance, the fault rate lambda of a single device at the time ti+1(t) is:
λi+1(t)＝biλi(t+aiTi)t∈(0,Ti+1)
biincreasing the factor for the failure rate of the device, and biThe increasing speed of the failure rate of the equipment can be estimated by applying a failure rate increasing factor; a isiIs a work age reduction factor of the plant and 0 < ai< 1, an initial value of the failure rate of the plant after non-complete maintenance can be obtained by a reduction factor of the working age; and T is the maintenance period of the equipment, and is the time interval between the maintenance period of the equipment and the working time.
The failure rate of a production line can be estimated by analyzing the failure rate of each device, and the failure of different devices can cause the production line to have different degrees of failure, and particularly, once the critical important devices have failed, serious conditions can cause the production line to stop production. Determining the influence coefficient omega according to the influence degree of each equipment on the production line, and then after the ith maintenance, at the moment t, determining the fault rate gamma of the production linei+1(t) can be estimated as:
wherein j is the equipment serial number in the production line, and n is the total number of the equipment in the production line.
The physical efficiency performance index is used for measuring the management level of the production line and indicates the shutdown time of the equipment under the condition of removing external factors and excluding all external reasons. The index calculation mainly takes logistics turnover equipment as a main part.
The energy consumption calculation method comprises the following steps: the energy consumption is used for counting the energy consumption in the operation process of the workshop production line, comprising electric quantity consumption, cooling liquid consumption and lubricating liquid consumption, wherein,
the electricity consumption in the same day is the electricity meter data in the same day-the electricity meter data in yesterday
The daily coolant consumption is equal to the daily coolant total-yesterday coolant total
The daily lubricating fluid consumption is equal to the total daily lubricating fluid-yesterday lubricating fluid
By integrating the daily consumption, monthly and annual energy consumption values can be obtained.
The performance is evaluated by using a single index, different enterprises have different concerned indexes, the evaluation is hooked with the characteristics of the enterprises, the evaluation can be only analyzed according to the specific conditions encountered by the objects, and a general method can adopt an analytic hierarchy process to evaluate.
(5) Production line control service module
The production line control service module receives an externally input equipment control instruction, and issues the equipment control instruction to corresponding equipment in an actual production line to control the state of the equipment.
The production line control service module comprises three parts of instruction receiving, instruction interpretation and instruction sending, wherein the instruction receiving part receives a numerical control program input from the outside and sends the numerical control program to the instruction interpretation part; the instruction interpretation part interprets a specific zone bit in the numerical control program instruction, judges a receiving object of the program and sends a judgment result to the instruction sending part; the instruction sending part sends the equipment control instruction to corresponding equipment in the actual production line through a data interface module in the data acquisition module to control the state of the equipment.
Example 1:
the principle and operation of the present invention will be described in detail by way of example with reference to fig. 1: the digital twin production line in the embodiment comprises 1 line edge library and 2 processing units. The line side warehouse consists of 1 finished product warehouse and 3 semi-finished product warehouses; one processing unit consists of 1 three-degree-of-freedom mechanical arm, 1 zigzag conveyor belt and 2 machine tools, and the other processing unit consists of 1 six-degree-of-freedom mechanical arm and 3 machine tools. It should be noted that the structural composition of the workshop production line is not limited to this, and other structural forms are also possible.
As shown in fig. 1, the production line digital twin system in this embodiment specifically includes the following steps:
the real-time data acquisition module acquires online data and actual running state information of a workshop production line at a fixed frequency in real time by using various sensors and industrial acquisition protocols, wherein the information comprises equipment states, personnel states, product states, logistics states, energy states and the like. In the embodiment, firstly, the requirement and the acquisition frequency of the acquired data of each sensor are determined according to the dynamic signal requirement of the production line to be monitored; the state data of the line side library comprises: warehousing time of each batch of products, quantity of warehoused products of each batch, ex-warehouse time of each batch of products, quantity of ex-warehouse products of each batch and quantity of real-time warehouse locations; the status data of 2 robots include: the real-time position, the running time and the on-off state of the equipment are determined; the state data of the machine tool includes: equipment running time, single-procedure processing time and equipment on-off state; the status data of the conveyor belt includes: the equipment on-off state and the equipment running time;
the state information data is uniformly packaged, stored and sent through an enterprise internal private network, message issuing service is provided through an MQTT protocol, and digital communication between a workshop production line and a virtual production line is established.
The industrial information model module stores and manages a three-dimensional geometric model, a physical information model, a functional information model and a performance information model of each component in the production line. Taking the machine tool in the embodiment as an example, the three-dimensional geometric model is designed through UG and 3DMAX three-dimensional industrial software; the information of the physical information model comprises the linkage relation of the physical material, the volume, the weight and the motion mechanism of the machine tool; the information of the function information model comprises the functions of the equipment (turning/milling/detection), the purposes, the brand and the in-service time; the performance information model comprises the productivity, the maximum load, the rotating speed, the precision, the cooling time, the calibration time, the maintenance period and the equipment failure rate information of the equipment.
In this embodiment, an industrial information model of each part of equipment such as a line side library, a conveyor belt, a robot, a processing unit and the like is respectively established, a virtual production line corresponding to an actual production line is established in a human-computer interaction module, the layout and the production process of the actual production line of a workshop are simulated, and a physical information model, a functional information model and a performance information model of each part are bound on a geometric model in a form of adding attributes. On one hand, the man-machine interaction module receives the production line state data sent by the real-time data acquisition module based on the MQTT protocol, and decomposes the production state data of the actual production line to obtain the actual production state data of each part related to the actual production line; on the other hand, based on the production line motion control display program written in C #, the analyzed actual production state data is called, interpolation processing is carried out on the actual production state data corresponding to the component, virtual production state data is obtained, finally, according to the virtual production state data, a geometric model in the virtual production line is controlled to complete simulation actions such as carrying, cutting and detecting, dynamic simulation of the production process of the production line is achieved, and meanwhile, the production state data corresponding to the component is expressed on an interface in real time.
In the embodiment, the pose and state control of the six-degree-of-freedom industrial robot model in the human-computer interaction module is completed by a motion control program display program, and the program takes the acquired actual rotation angle of the industrial robot and the actual displacement data of the robot on a plane as input data, controls the industrial robot model in the virtual production line to move to a target position, controls the manipulator to rotate to the target pose, and realizes the simulation of the loading and unloading action and the displacement action of the robot in the virtual production line driven by the actual data. The method can realize the problems of real-time simulation, virtual monitoring and the like of the production state of the production line.
The production line performance evaluation module adopts an analytic hierarchy process to evaluate the comprehensive performance of the production line, and the comprehensive performance comprises capacity evaluation, resource balance, fault prediction, logistics efficiency and energy consumption. In the embodiment, the productivity and resource balance of the production line are evaluated, the material conveying route of the robot is optimized on the basis of the logistics efficiency, the overall logistics efficiency of the production line is improved, the overhaul and maintenance time of the machine tool is planned through fault prediction, and the production stability of a workshop is improved.
The production line control service module receives an externally input equipment control instruction and issues the equipment control instruction to corresponding equipment in an actual production line to control the equipment state, wherein the control instruction comprises an equipment instruction, a personnel instruction, a logistics instruction, a scheduling instruction and an energy instruction. In the embodiment, the processing program of the machine tool, the operation instruction of personnel and the operation program of the robot can all issue instructions through the production line service control module.
Compared with the prior art, the invention has the beneficial effects that: the production line digital twin system provided by the invention drives the twin system by production line actual data to realize dynamic simulation, virtual monitoring, performance evaluation and service control in the production process, not only solves the problems of real-time simulation, virtual monitoring and evaluation optimization of the production line, but also realizes the virtual-real interaction function of the production line entity and the production line twin body, improves the integrated and visual management level of the workshop production line, and has good application prospect.
The present invention may be embodied in many different forms and is not limited to only the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. It is to be noted that, unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention, as those skilled in the art will recognize other embodiments of the invention without undue experimentation based on the explanation herein, which will fall within the scope of the invention.
Claims (8)
1. A production line digital twinning system, comprising: the system comprises a real-time data acquisition module, an industrial information model module, a man-machine interaction module, a production line performance evaluation module and a production line control service module; wherein:
the real-time data acquisition module is used for receiving production state data acquired by an actual production line in real time and forwarding the production state data to the man-machine interaction module and the production line performance evaluation module;
the production state data comprises equipment state, personnel state, product state, logistics state and energy state data;
the device status data includes: equipment running time, single-procedure processing time and equipment on-off state;
the personnel status includes: personnel real-time position, personnel working time, personnel number and personnel job number;
the product state comprises: the number of products in process, the type of products in process, the number of products in process and the daily output of various products;
the logistics state comprises the following steps: the real-time position of a product being processed, the real-time position of logistics equipment, the working time of the logistics equipment, the standby time of the logistics equipment, the warehousing time of each batch of products, the quantity of warehoused products in each batch, the ex-warehouse time of each batch of products, the quantity of ex-warehouse products in each batch and the quantity of real-time warehouse locations;
the energy state information comprises: workshop electric meter data, cooling liquid usage amount and lubricating liquid usage amount;
the system comprises an industrial information model module, a data processing module and a data processing module, wherein the industrial information model module is used for constructing, storing and managing information models of parts related to an actual production line, the information models comprise a geometric model, a physical information model, a functional information model, a performance information model and a rule information model, and the rule information model comprises a production line balance principle and a substitution principle and is used for standardizing the adjustment flow of the production line and ensuring the rationality of the production line in the adjustment process;
the human-computer interaction module is used for receiving the production line state data sent by the real-time data acquisition module and decomposing the production state data of the actual production line to obtain the actual production state data of each part related to the actual production line; establishing a virtual production line corresponding to the actual production line, namely: the digital twin production line is realized by instantiating a geometric model corresponding to a related component in an actual production line in an industrial information model module, the geometric model binds a physical information model, a functional information model, a performance information model and a motion control display program of the component in the form of attributes, the motion control display program of each component extracts actual production state data corresponding to the component, interpolation processing is carried out on the actual production state data corresponding to the component to obtain virtual production state data, the geometric model is controlled to move, rotate and change to complete simulation actions according to the virtual production state data to realize dynamic simulation of the production process of the production line, and meanwhile, the production state data corresponding to the component is visually expressed on an interface in the form of a chart;
the production line performance evaluation module is used for receiving the production state data sent by the real-time data acquisition module, taking the data as input data, automatically calculating and displaying each single index value by using each single performance index calculation method of the actual production line, and performing overall evaluation on the comprehensive performance of the actual production line according to each single index value;
and the production line control service module receives an externally input equipment control instruction, issues the equipment control instruction to corresponding equipment in the actual production line, and controls the working state of the equipment.
2. A production line digital twinning system as claimed in claim 1, wherein: the real-time data acquisition module comprises three parts of data acquisition, data management and data communication, wherein the data acquisition part acquires production state data in a workshop production line and sends the production state data to the data management part; the data management part backs up, encapsulates and stores the acquired state data; the data communication part is used as a data server, provides message publishing service for the man-machine interaction module used as a data subscription client according to a message queue telemetry transmission protocol, and sends the data encapsulated in the data management part to the man-machine interaction module, so that the digital communication between the production line site and the digital twin system is realized.
3. A production line digital twinning system as claimed in claim 1, wherein:
for equipment, the physical information model comprises linkage relation information of physical materials, volume, weight and motion mechanisms; the function information model comprises the function, the use, the brand and the in-service time information of the equipment; the performance information model comprises the production capacity, the maximum load, the rotating speed, the precision, the cooling time, the calibration time, the maintenance period and the equipment failure rate information of the equipment;
for a person, the physical information model comprises a skeleton model and a joint action state of the person; the functional information model comprises personnel functions, operation skills and management authority information; the performance information model comprises age, working age, proficiency, work efficiency and work cycle information;
for the material, the physical information model comprises material attribute, appearance color, volume and weight information of the material; the functional information model comprises material serial number, material usage and processing requirement information; the performance information model comprises processing procedure and warehouse-in and warehouse-out inspection requirement information;
for a product, the physical information model comprises material attribute, appearance color, volume and weight information; the function information model comprises product use, model and number information; the performance information model comprises assembly precision and performance parameter information.
4. The production line digital twinning system as claimed in claim 1, wherein said motion control display program includes a motion simulation module and a process monitoring module;
the motion simulation module periodically extracts actual production state data of the corresponding component, performs interpolation processing on the actual production state data based on the kinematics principle of the component to obtain virtual production state data, and sends the virtual production state data to the process monitoring module;
and the process monitoring module simulates the real-time state of the corresponding part of the actual production line according to the virtual production state data and displays the real-time state on a screen to realize the virtual monitoring of the real-time production process of the production line.
5. A production line digital twinning system as claimed in claim 1, wherein: the production line performance evaluation module comprises three parts of data processing, index calculation and comprehensive evaluation, wherein the data processing part receives and processes actual production line production state data sent by the real-time data acquisition module and sends the data to the index calculation part; the index calculation part integrates a calculation method of a plurality of production line single performance indexes, receives input data sent by the data processing part, automatically substitutes the input data into the data to calculate and display a calculation result, and forwards the single performance index result to the comprehensive evaluation part; and a performance evaluation module of the comprehensive evaluation part takes the calculation results of the single performance indexes as input according to a preset evaluation standard, adopts a hierarchical analysis method to obtain a comprehensive performance evaluation score, and performs overall evaluation on the comprehensive performance of the production line.
6. A production line digital twinning system as claimed in claim 1, wherein: the production line control service module comprises three parts of instruction receiving, instruction interpretation and instruction sending, wherein the instruction receiving part receives a numerical control program input from the outside and sends the numerical control program to the instruction interpretation part; the instruction interpretation part interprets a specific zone bit in the numerical control program instruction, judges a receiving object of the program and sends a judgment result to the instruction sending part; the instruction sending part sends the equipment control instruction to corresponding equipment in the actual production line through a data interface module in the data acquisition module to control the state of the equipment.
7. The production line digital twinning system of claim 1, wherein said digital twinning production line is implemented using a Unity 3D-based physical engine.
8. The production line digital twinning system of claim 1, wherein the human-computer interaction interface is constructed using a WFP interface framework.
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| CN110879583A (en) * | 2019-12-26 | 2020-03-13 | 江苏古卓科技有限公司 | Intelligent assembly workshop quality prediction and control system and method based on digital twins |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11971797B2 (en) | 2020-12-01 | 2024-04-30 | Fu Tai Hua Industry (Shenzhen) Co., Ltd. | Digital mirroring method, server, and storage medium |
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