CN112132359A - Digital twin satellite pulsating assembly workshop design method and system - Google Patents
Digital twin satellite pulsating assembly workshop design method and system Download PDFInfo
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Abstract
The invention discloses a design method and a system of a digital twin satellite pulsating assembly workshop, wherein the method comprises the following steps: designing a secondary packaging design module based on digital twinning, wherein the module is used for completing the design and packaging of a final assembly station and a final assembly workshop; designing a digital twin virtual-real interactive debugging module, wherein the module realizes debugging of a model, an interface and a system by establishing real-time data connection with a physical entity; designing a final assembly worker model base to realize the analysis and prediction of the process completion time, the process matching degree and the individual fatigue degree of the final assembly workers; the design process simulation analysis module is used for carrying out simulation verification on the design scheme and optimizing and correcting the defect scheme; and designing a digital twin system instantiation module, instantiating the design and outputting the design as a modular component to guide workshop construction and system development. The method can improve the design efficiency and effectiveness of the satellite pulse type assembly workshop to a certain extent according to the characteristics of the satellite pulse type assembly workshop.
Description
Technical Field
The invention belongs to the field of industrial digitization and computer science, and particularly relates to a design method and a system of a digital twin satellite pulsating assembly workshop.
Background
The satellite final assembly is a crucial part in the satellite development process, and the final quality of the satellite is influenced. With the rapid development of commercial transformation in the satellite industry, the assembly model of the conventional satellite fixed station has difficulty in meeting the requirements and challenges of low-cost, short-cycle, large-batch and highly customized development. The pulsating assembly mode is an assembly mode of intermittent movement in a rhythm between continuous movement assembly and fixed assembly, and the assembly mode that a specific station completes a specific process and a satellite product moves among different stations to complete an assembly task is formed by deconstructing and redesigning a traditional process. The pulsating assembly mode greatly improves the assembly efficiency, is more favorable for lean management of the assembly process, is convenient for improving the digitization, automation and intelligence level of the whole system, and is an effective mode for meeting the future development requirements and challenges of the satellite assembly.
In the aspect of workshop design, design and optimization are generally carried out by means of a digital model of equipment or units, verification and analysis are carried out on a scheme by means of off-line simulation or semi-real-time simulation, and finally a design scheme is formed. These techniques have the following problems in designing for satellite pulsed assembly production: the existing design method is mainly designed for a flow production line, is limited for a pulsating assembly workshop of complex products such as satellites and the like, and lacks consideration on factors such as operation time, proficiency, fatigue and the like of personnel in discrete assembly; secondly, the problems of inconsistency, inaccuracy and the like of a digital model of the existing design method with an actual scene and equipment generally exist, and the credibility of a design result is reduced; off-line simulation and semi-real-time simulation of the existing design method are usually disconnected from the work order process in the actual assembly production; the existing design method has a lack in communication network design and control mechanism design; the conversion rate of the design scheme achievement of the existing design method is not high during the construction of the actual final assembly workshop, and the models, interfaces, control mechanisms and the like generated during the design can not be directly or indirectly converted into one part of the final assembly workshop management and control system.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the existing design method is mainly designed for a flow production line, is limited for a pulsating assembly workshop of complex products such as satellites and the like, and lacks consideration on factors such as operation time, proficiency, fatigue and the like of personnel in discrete assembly; secondly, the problems of inconsistency, inaccuracy and the like of a digital model of the existing design method with an actual scene and equipment generally exist, and the credibility of a design result is reduced; off-line simulation and semi-real-time simulation of the existing design method are usually disconnected from the work order process in the actual assembly production; the existing design method has a lack in communication network design and control mechanism design; the conversion rate of the design scheme achievement of the existing design method is not high during the construction of the actual final assembly workshop, and the models, interfaces, control mechanisms and the like generated during the design can not be directly or indirectly converted into one part of the final assembly workshop management and control system. Therefore, the invention aims at the problems, improves the traditional design method by means of the digital twin technology, and improves the efficiency, accuracy, credibility, coverage and guidance of design to a certain extent.
The technical problem to be solved by the invention is realized by adopting the following technical scheme: a design method of a digital twin satellite pulsating assembly workshop comprises the following steps:
step (1), designing a digital twin-based secondary packaging design module, wherein the module is specifically realized as follows:
(1.1) firstly, analyzing and decoupling a satellite pulse type general assembly workshop process, determining a specific process of each assembly station and a process relation among different assembly stations, designing an assembly station model comprising station equipment, a layout, an operation mechanism and behavior rules, designing a communication interface among equipment actuators, sensors and an upper computer, and signing a control mechanism script of a propulsion mechanism by using mechanical motion and paths, a mechanical automatic control mechanism and an assembly process of the assembly stations;
(1.2) integrating the designed assembly station model, communication interface and control mechanism script, and integrally packaging the assembly station model, communication interface and control mechanism script into an assembly station digital twin model, wherein the assembly station digital twin model can be used for position adjustment, model interaction, interface debugging and mechanical motion simulation;
(1.3) realizing modular design with assembly stations as units based on the packaged digital twin models of the assembly stations, wherein the modular design comprises general assembly workshop layout design and logistics design based on a three-dimensional model of the assembly stations, workshop communication network architecture design based on communication interfaces of the assembly stations, and workshop process flow control logic design based on control mechanism scripts to obtain a designed general assembly workshop model, a communication network, a logistics scheme and control logic;
(1.4) integrating a final assembly workshop model, a communication network, a logistics scheme and control logic which are designed and developed, and integrally packaging the final assembly workshop model, the communication network, the logistics scheme and the control logic into a final assembly workshop digital twin model;
step (2), designing a digital twin virtual-real interaction debugging module, wherein the module is specifically realized as follows:
(2.1) establishing data communication between a physical entity related in the design of the final assembly workshop and a digital twin virtual model, wherein the digital twin virtual model comprises an assembly station digital twin model and a final assembly workshop digital twin model;
(2.2) under the excitation of the same signal, acquiring feedback data of the physical entity and the digital twin virtual model, calculating a difference value between the physical entity and the digital twin virtual model, and judging whether the difference value is within a system allowable threshold value;
(2.3) if the digital twin virtual model is not within the allowable threshold, correcting the digital twin virtual model, and performing signal excitation and difference judgment again;
(2.4) if within the allowable threshold, outputting the digital twin virtual model;
step (3), designing a final assembly worker model base, modeling relevant process operation of workers based on historical data by the model base, and comprising a process average completion time prediction model PaProcess completion time prediction model P based on individual proficiencypWorker-station matching degree model P based on individual operation capacitymFatigue degree prediction model P based on individual body energyf；
Step (4), designing a process simulation analysis module, wherein the module is specifically realized as follows:
(4.1) taking an assembly work order, real-time or historical data of equipment and real-time or historical operating records of personnel as simulation driving scripts, importing a digital twin model and a general assembly worker model of a general assembly workshop, and simulating a pulsating general assembly process of the satellite;
(4.2) analyzing the function, performance, feasibility and reliability of the final assembly workshop design by means of simulation result parameters, and judging whether the design scheme needs to be corrected and optimized according to various indexes;
(4.3) if optimization is needed, determining an optimization target and an index, optimizing the design of the assembly workshop by means of a multi-objective optimization algorithm and the like to form a correction strategy for the design of the assembly workshop, and returning the strategy to the secondary packaging design module based on the digital twin in the step 1 for redesign;
(4.4) if the optimization is not needed, outputting the final assembly workshop design model;
and (5) designing a digital twin system instantiation module, instantiating a final assembly workshop design model to form a final assembly workshop layout model, a network architecture and interface model, a logistics scheme and control strategy, a workshop control script and a worker process task allocation strategy, and guiding the on-site construction, installation and debugging of an assembly line and the construction of a digital twin workshop system.
Preferably, the assembly station digital twin model of step 1 comprises: the model covers various objects of a field, personnel, materials, equipment and tools of an assembly station; firstly, constructing an assembly station three-dimensional model, wherein the three-dimensional models of equipment and tools are independent and movable, and are combined with a station scene model to carry out layout design to construct the assembly station three-dimensional model; secondly, constructing a data model of each object, developing and associating a related data interface, and ensuring the acquisition, processing and storage of data; then, constructing a mechanical motion model, a physical attribute model, a rule model and a control mechanism script of each object, wherein a model is established for the incidence relation between the operation of a person and equipment and products so as to reflect the influence of the operation of the person on the assembly process; the digital description of the assembly station is realized through the models, and finally, incidence relations and interaction relations are established for all the models.
Preferably, the assembly shop digital twin model of step 1 includes: the model covers various objects of a field, personnel, materials, equipment, tools and products of the final assembly workshop; firstly, constructing a final assembly workshop three-dimensional model, and on the basis of the assembly station three-dimensional model, constructing the final assembly workshop three-dimensional model together by designing and arranging the positions of all stations and combining the three-dimensional design of logistics distribution routes, logistics storage and product storage; secondly, designing a workshop communication network architecture based on a data interface of an assembly station, carrying out interface debugging and association on a data model of the assembly station, adding data models of products, logistics, processes and environments, and constructing and forming a data model of a final assembly workshop; then, constructing a logistics equipment motion model, a product quality model, a workshop operation and maintenance rule model, a workshop control mechanism script and a workshop environment model; the digital description of the final assembly workshop is realized through the models, and finally, the association relation and the interaction relation are established for all the models.
Preferably, the virtual-real interactive debugging in step 2 includes: the developed model, the communication interface and the control mechanism script are communicated and debugged with the corresponding physical entity, the physical entity has the problem of self fault before being accessed into the module, the debugged physical entity is guaranteed to be reliable, meanwhile, the information communication is real-time and reliable, and the station and workshop digital twin model is verified under the excitation of the same signal, so that the consistency of the geometric dimension of the three-dimensional model, the motion behavior of the mechanical motion model, the data relation of the data model, the attribute characteristics of the physical attribute model, the rule and the boundary of the rule model and the actual station and equipment is ensured.
Specifically, the final assembly worker model library in step 3 includes: A. process mean time to completion prediction model PaThe system is used for predicting the completion time of different processes on an assembly station so as to assist in process propulsion, general assembly flow management, time prediction of logistics distribution and management and control strategy design; B. process completion time prediction based on individual proficiencyModel PpFor making a time to completion prediction for a process that is partially dependent on the proficiency of an individual's manual work; C. worker-station matching degree model P based on individual operation capacitymThe method is used for realizing station process distribution according to the skill characteristics of workers; D. fatigue degree prediction model P based on individual body energyfThe method is used for predicting the fatigue of workers so as to realize the scheduling of the workers in the general assembly process and the process completion time prediction based on the scheduling.
Preferably, the multi-objective optimization algorithm based final assembly shop optimization of the step 4 includes: performing multi-aspect simulation analysis on the final assembly process to judge whether design defects exist in station process execution, station layout, logistics distribution and workshop scheduling; aiming at design defects, the indexes to be optimized and related constraints are analyzed, mathematical expressions of a target function, an index function and a constraint function are established, a proper multi-objective optimization algorithm is selected, mathematical model conversion is carried out on the design model to form an algorithm available model, a corresponding optimal solution or a pareto optimal solution is formed through multi-objective optimization, and a general assembly shop design correction strategy is formed by combining engineering practical conditions.
Specifically, the digital twin system instantiation in step 5 includes: A. the assembly workshop layout model comprises an assembly line scene layout diagram, an equipment layout diagram and a logistics path diagram and is used for guiding the construction of a field site and the construction of a digital twin satellite pulsating assembly workshop system model; B. the network architecture scheme and the network interface script are used for guiding the construction of a field communication network, including network routing, interface configuration and protocol development; C. the logistics control scheme and the logistics equipment control script are used for guiding the building of a logistics system, the establishment of a logistics strategy, the configuration of logistics equipment on the assembly site and the building of an assembly line MES system; D. the station equipment automatic control scheme and the station equipment control script are used for guiding the formulation of an assembly line and a specific station control scheme and the system building of an assembly line MES system and a station MES subsystem; E. the worker process task allocation is used for guiding site worker station allocation, process allocation and worker scheduling.
According to another aspect of the present invention, a digital twin satellite pulsating assembly shop design system is provided, which includes:
A. a secondary packaging design module based on digital twin, which comprises a plurality of standardized model libraries, a model construction tool, a communication network design tool, a control logic design tool and a three-dimensional graphical interactive interface, supports the design and packaging of a model, a communication interface and a control mechanism of an assembly station, sets the position of the assembly station in a general assembly workshop, and designs and packages logistics logic, a logistics route and a control mechanism script of logistics equipment;
B. the digital twin virtual-real interactive debugging module accesses the physical entity and the virtual model into a system through a data interface to realize acquisition of homologous data of the physical entity and the virtual model, simultaneously comprises a process operation instruction library and an operation control instruction library, sends the same instruction as an excitation signal to the physical entity and the virtual model, verifies feedback output and difference value of the physical entity and the virtual model, and provides a correction suggestion for the virtual model exceeding an allowable threshold;
C. the general assembly worker model base is constructed according to historical operation data of general assembly field workers, can be called by other modules and is updated according to the accumulation degree of the historical data;
D. the process simulation analysis module converts the assembly work order into a simulation script, drives the simulation data by using real-time or historical data of equipment and real-time or historical operation records of personnel, simulates a network function, a station function, a logistics function and an entire line operation function of a final assembly design model by combining a final assembly worker model, verifies the production capacity of a final assembly workshop under different conditions and generates a simulation result; analyzing a simulation result, performing target function, index function, constraint function setting and multi-objective optimization algorithm selection on a model needing to be corrected and optimized, optimizing a design model and forming a correction strategy;
E. and the digital twin system instantiation module instantiates and outputs the final assembly workshop design model as a design scheme, the scheme comprises an assembly line scene layout diagram, a network architecture scheme, a network interface script, a logistics path diagram, a logistics control scheme, a logistics equipment control script, a station equipment automatic control scheme and a station equipment control script, and meanwhile, the final assembly workshop digital twin model and the assembly station digital twin model are beneficial to constructing the digital twin of the actual final assembly workshop.
Compared with the prior art, the invention has the advantages that:
(1) a digital twin secondary packaging design mechanism is provided, a distributed and modularized design architecture is formed, the design efficiency of a final assembly workshop is improved, and meanwhile, the error correction, improvement and expansion of the design are facilitated;
(2) a digital twin virtual-real interactive debugging module is designed, so that the consistency and accuracy of a design model are ensured to a certain extent, and the credibility of a design result is improved;
(3) the model base of the final assembly workers is designed, so that the problem that the traditional method is lack of consideration for factors such as the operation time, proficiency and fatigue of the workers is solved to a certain extent;
(4) in the process simulation analysis module, simulation analysis is carried out by means of an actual production work order, and an optimization correction strategy is formed, so that the relatively excellent and accurate design result is ensured to a certain extent;
(5) and a digital twin system instantiation module is designed, so that the conversion rate and the coverage rate of a design scheme result in the construction of an actual final assembly workshop are improved to a certain extent.
Drawings
FIG. 1 is a flow chart of a design method and a system of a digital twin satellite pulsating assembly workshop according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, rather than all embodiments, and all other embodiments obtained by a person skilled in the art based on the embodiments of the present invention belong to the protection scope of the present invention without creative efforts.
According to one embodiment of the invention, the design method of the digital twin satellite pulsating assembly workshop specifically comprises the following steps:
(1) designing a digital twin-based two-level packaging design module, which is specifically realized as follows:
firstly, analyzing and decoupling a satellite pulse type general assembly workshop process, determining a specific process of each assembly station and a process relation among different assembly stations, designing an assembly station model comprising station equipment, a layout, an operation mechanism and behavior rules, a communication interface among each equipment actuator, a sensor and an upper computer, and signing a control mechanism script of a propulsion mechanism by mechanical motion and path, a mechanical automatic control mechanism and the assembly process of the assembly stations;
integrating the designed assembly station model, communication interface and control mechanism script, and integrally packaging the assembly station model, communication interface and control mechanism script into an assembly station digital twin model, wherein the assembly station digital twin model can perform position adjustment, model interaction, interface debugging and mechanical motion simulation;
realizing modular design with assembly stations as units based on the packaged digital twin models of the assembly stations, wherein the modular design comprises assembly workshop layout design and logistics design based on the three-dimensional models of the assembly stations, workshop communication network architecture design based on the communication interfaces of the assembly stations, and workshop process flow control logic design based on control mechanism scripts to obtain a designed assembly workshop model, a communication network, a logistics scheme and control logic;
integrating the designed and developed final assembly workshop model, communication network, logistics scheme and control logic, and integrally packaging the final assembly workshop model, communication network, logistics scheme and control logic into a final assembly workshop digital twin model;
(2) designing a digital twin virtual-real interactive debugging module, wherein the module is specifically realized as follows:
establishing data communication between a physical entity involved in the design of a final assembly workshop and a digital twin virtual model, wherein the digital twin virtual model comprises an assembly station digital twin model and a final assembly workshop digital twin model;
under the excitation of the same signal, acquiring feedback data of the physical entity and the digital twin virtual model, calculating a difference value between the physical entity and the digital twin virtual model, and judging whether the difference value is within a system allowable threshold value;
if the digital twin virtual model is not within the allowable threshold, correcting the digital twin virtual model, and performing signal excitation and difference judgment again;
if the number of the twin virtual models is within the allowable threshold, outputting the digital twin virtual models;
(3) designing a final assembly worker model base, modeling relevant process operation of workers based on historical data, and comprising a process average completion time prediction model PaProcess completion time prediction model P based on individual proficiencypWorker-station matching degree model P based on individual operation capacitymFatigue degree prediction model P based on individual body energyf；
(4) The design process simulation analysis module is specifically realized as follows:
firstly, taking an assembly work order, real-time or historical data of equipment and real-time or historical operation records of personnel as simulation driving scripts, importing a digital twin model and a general assembly worker model of a general assembly workshop, and simulating a satellite pulsating general assembly process;
analyzing the function, performance, feasibility and reliability of the design of the final assembly workshop by means of simulation result parameters, and judging whether the design scheme needs to be corrected and optimized according to various indexes;
thirdly, if optimization is needed, determining an optimization target and an index, optimizing the design of the assembly workshop by means of a multi-target optimization algorithm and the like to form a correction strategy for the design of the assembly workshop, and returning the strategy to the secondary packaging design module based on the digital twin in the step 1 for redesign;
fourthly, if the optimization is not needed, outputting the design model of the final assembly workshop;
(5) and designing a digital twin system instantiation module, instantiating the assembly workshop design model to form an assembly workshop layout model, a network architecture and interface model, a logistics scheme and control strategy, a workshop control script and a worker process task distribution strategy, and guiding the assembly line field construction, installation and debugging and the digital twin workshop system construction.
The specific implementation of the digital twin model of the assembly station and the final assembly workshop comprises the following steps: the model covers various objects such as the field, personnel, materials, equipment, tools, products and the like of the assembly station and the final assembly workshop. In order to realize the digital expression of the assembly stations and the final assembly workshop, firstly, a three-dimensional model of the scene of the whole assembly station is constructed, wherein the three-dimensional models of equipment and tools are independent and movable, are constructed through modeling software such as CAD (computer-aided design) and ProE (ProE), are imported into a program driven by the same image engine, are subjected to layout design by combining with the scene model of the station, and are constructed into the three-dimensional model of the assembly stations; secondly, constructing a data model of each object of the assembly station, developing and associating a related data interface, ensuring the collection, processing and storage of data, defining the data expression and relationship of each object by virtue of UML, designing and realizing a database in MySQL, associating the database with the three-dimensional model, further designing a workshop communication network architecture by virtue of OPNET and OMNeT + +, debugging and associating the interface of the data model of the assembly station, adding a data model of a product, logistics, a process and an environment, and constructing and forming a data model of a final assembly workshop; and then, constructing a mechanical motion model, a physical attribute model, a rule model and a control mechanism script of each object of the assembly station, a logistics equipment motion model, a product quality model, a workshop operation and maintenance rule model, a workshop control mechanism script and a workshop environment model of the assembly workshop by means of action skeleton setting, action node setting, motion boundary setting, control script importing and the like, wherein a model is established for the incidence relation between human operation and equipment and products so as to reflect the influence of the human operation on the assembly process. The comprehensive digital description of the assembly station and the final assembly workshop is realized through the models, and finally, the incidence relation and the interaction relation are established for all the models.
The virtual-real interactive debugging concrete implementation comprises the following steps: the developed model, the communication interface and the control mechanism script are communicated and debugged with the corresponding physical entity, the problem that the physical entity has faults before being accessed into the module is solved, the debugged physical entity is reliable and credible, and meanwhile, the information communication is real-time and reliable. And (3) verifying and verifying the digital twin model of the station and the workshop under the same signal excitation, and ensuring the consistency of the geometric dimension of the three-dimensional model, the motion behavior of the mechanical motion model, the data relation of the data model, the attribute characteristics of the physical attribute model, the rule and the boundary of the rule model with the actual station and the equipment.
The specific implementation of the final assembly worker model library comprises the following steps: process mean time to completion prediction model PaAnd a process completion time prediction model P based on individual proficiencypThe method is constructed based on historical data of worker process operation, a specific method is determined according to the sample size of the historical data, when the sample size is small, modeling is carried out based on a grey theory, and when the sample size is large, modeling is carried out by adopting a convolutional neural network; worker-station matching degree model P based on individual operation capacitymAnalyzing historical operation data of workers by means of data mining, judging the adaptability to different processes, and further determining the matching degree with different stations; fatigue degree prediction model P based on individual body energyfAnd establishing fatigue degree prediction curves of each person in different working states by collecting body health parameters of the workers during working.
The overall assembly workshop optimization specific implementation based on the multi-objective optimization algorithm comprises the following steps: and performing multi-aspect simulation analysis on the final assembly process to judge whether design defects exist in the aspects of station process execution, station layout, logistics distribution and workshop scheduling. Aiming at design defects, the indexes to be optimized and related constraints are analyzed, mathematical expressions of a target function, the index function and a constraint function are established, a proper multi-objective optimization algorithm is selected from algorithms such as SPEA2, PESA-II, NSGA-II and the like, mathematical model conversion is carried out on a design model to form an algorithm available model, a corresponding optimal solution or pareto optimal solution is formed through multi-objective optimization, and a general assembly shop design correction strategy is formed by combining engineering practical conditions.
The instantiation implementation of the digital twin system comprises the following steps:
A. aiming at a general assembly workshop layout model comprising an assembly line scene layout diagram, an equipment layout diagram and a logistics path diagram, forming a corresponding three-dimensional design drawing by carrying out information marking, rendering and format conversion on a three-dimensional model;
B. aiming at a network architecture scheme and a network interface script, the network architecture design scheme, IP interface allocation, a network equipment field arrangement scheme, a software and hardware data interface and the like are associated and output;
C. aiming at a logistics control scheme and a logistics equipment control script, a logistics field equipment layout diagram, a logistics system architecture, logistics equipment configuration, a logistics emergency scheme and the like are associated and output;
D. aiming at the automatic control scheme and the control script of the station equipment, the control logic diagram, part of the bottom layer control script and the equipment path planning scheme of each equipment are associated and output;
E. aiming at the distribution of the worker process tasks, the worker station distribution, the process distribution and the worker scheduling table formed by simulation analysis are output.
According to another embodiment of the present invention, a digital twin satellite pulsating assembly shop design system is provided, which specifically includes:
A. a secondary packaging design module based on digital twin, which comprises a plurality of standardized model libraries, a model construction tool, a communication network design tool, a control logic design tool and a three-dimensional graphical interactive interface, supports the design and packaging of a model, a communication interface and a control mechanism of an assembly station, sets the position of the assembly station in a general assembly workshop, and designs and packages logistics logic, a logistics route and a control mechanism script of logistics equipment;
B. the digital twin virtual-real interactive debugging module accesses the physical entity and the virtual model into a system through a data interface to realize acquisition of homologous data of the physical entity and the virtual model, simultaneously comprises a process operation instruction library and an operation control instruction library, sends the same instruction as an excitation signal to the physical entity and the virtual model, verifies feedback output and difference value of the physical entity and the virtual model, and provides a correction suggestion for the virtual model exceeding an allowable threshold;
C. the general assembly worker model base is constructed according to historical operation data of general assembly field workers, can be called by other modules and is updated according to the accumulation degree of the historical data;
D. the process simulation analysis module converts the assembly work order into a simulation script, drives the simulation data by using real-time or historical data of equipment and real-time or historical operation records of personnel, simulates a network function, a station function, a logistics function and an entire line operation function of a final assembly design model by combining a final assembly worker model, verifies the production capacity of a final assembly workshop under different conditions and generates a simulation result; analyzing a simulation result, performing target function, index function, constraint function setting and multi-objective optimization algorithm selection on a model needing to be corrected and optimized, optimizing a design model and forming a correction strategy;
E. and the digital twin system instantiation module instantiates and outputs the final assembly workshop design model as a design scheme, the scheme comprises an assembly line scene layout diagram, a network architecture scheme, a network interface script, a logistics path diagram, a logistics control scheme, a logistics equipment control script, a station equipment automatic control scheme and a station equipment control script, and meanwhile, the final assembly workshop digital twin model and the assembly station digital twin model are beneficial to constructing the digital twin of the actual final assembly workshop.
In conclusion, the invention discloses a design method and a system for a digital twin satellite pulsating assembly workshop, which comprises a digital twin-based secondary packaging design module, a digital twin virtual-real interaction debugging module, an assembly worker model library, a process simulation analysis module and a digital twin system instantiation module, can solve the problems existing in the design of the current satellite pulsating assembly workshop to a certain extent, and improves the efficiency, accuracy, credibility, coverage and guidance of the design.
Those skilled in the art will appreciate that the invention may be practiced without these specific details.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (8)
1. A design method of a digital twin satellite pulse type general assembly workshop is characterized by comprising the following specific design steps:
step (1), designing a digital twin-based secondary packaging design module, wherein the module is specifically realized as follows:
(1.1) firstly, analyzing and decoupling a satellite pulse type general assembly workshop process, determining a specific process of each assembly station and a process relation among different assembly stations, designing an assembly station model comprising station equipment, a layout, an operation mechanism and behavior rules, designing a communication interface among equipment actuators, sensors and an upper computer, and signing a control mechanism script of a propulsion mechanism by using mechanical motion and paths, a mechanical automatic control mechanism and an assembly process of the assembly stations;
(1.2) integrating the designed assembly station model, communication interface and control mechanism script, and integrally packaging the assembly station model, communication interface and control mechanism script into an assembly station digital twin model, wherein the assembly station digital twin model can be used for position adjustment, model interaction, interface debugging and mechanical motion simulation;
(1.3) realizing modular design with assembly stations as units based on the packaged digital twin models of the assembly stations, wherein the modular design comprises general assembly workshop layout design and logistics design based on a three-dimensional model of the assembly stations, workshop communication network architecture design based on communication interfaces of the assembly stations, and workshop process flow control logic design based on control mechanism scripts to obtain a designed general assembly workshop model, a communication network, a logistics scheme and control logic;
(1.4) integrating a final assembly workshop model, a communication network, a logistics scheme and control logic which are designed and developed, and integrally packaging the final assembly workshop model, the communication network, the logistics scheme and the control logic into a final assembly workshop digital twin model;
step (2), designing a digital twin virtual-real interaction debugging module, wherein the module is specifically realized as follows:
(2.1) establishing data communication between a physical entity related in the design of the final assembly workshop and a digital twin virtual model, wherein the digital twin virtual model comprises an assembly station digital twin model and a final assembly workshop digital twin model;
(2.2) under the excitation of the same signal, acquiring feedback data of the physical entity and the digital twin virtual model, calculating a difference value between the physical entity and the digital twin virtual model, and judging whether the difference value is within a system allowable threshold value;
(2.3) if the digital twin virtual model is not within the allowable threshold, correcting the digital twin virtual model, and performing signal excitation and difference judgment again;
(2.4) if within the allowable threshold, outputting the digital twin virtual model;
step (3), designing a final assembly worker model base, modeling relevant process operation of workers based on historical data by the model base, and comprising a process average completion time prediction model PaProcess completion time prediction model P based on individual proficiencypWorker-station matching degree model P based on individual operation capacitymFatigue degree prediction model P based on individual body energyf；
Step (4), designing a process simulation analysis module, wherein the module is specifically realized as follows:
(4.1) taking an assembly work order, real-time or historical data of equipment and real-time or historical operating records of personnel as simulation driving scripts, importing a digital twin model and a general assembly worker model of a general assembly workshop, and simulating a pulsating general assembly process of the satellite;
(4.2) analyzing the function, performance, feasibility and reliability of the final assembly workshop design by means of simulation result parameters, and judging whether the design scheme needs to be corrected and optimized according to various indexes;
(4.3) if optimization is needed, determining an optimization target and an index, optimizing the design of the assembly workshop by means of a multi-objective optimization algorithm and the like to form a correction strategy for the design of the assembly workshop, and returning the strategy to the secondary packaging design module based on the digital twin in the step 1 for redesign;
(4.4) if the optimization is not needed, outputting the final assembly workshop design model;
and (5) designing a digital twin system instantiation module, instantiating a final assembly workshop design model to form a final assembly workshop layout model, a network architecture and interface model, a logistics scheme and control strategy, a workshop control script and a worker process task allocation strategy, and guiding the on-site construction, installation and debugging of an assembly line and the construction of a digital twin workshop system.
2. The design method of the digital twin satellite pulsating assembly workshop as claimed in claim 1, wherein the assembly station digital twin model of step 1 comprises: the model covers various objects of a field, personnel, materials, equipment and tools of an assembly station; firstly, constructing an assembly station three-dimensional model, wherein the three-dimensional models of equipment and tools are independent and movable, and are combined with a station scene model to carry out layout design to construct the assembly station three-dimensional model; secondly, constructing a data model of each object, developing and associating a related data interface, and ensuring the acquisition, processing and storage of data; then, constructing a mechanical motion model, a physical attribute model, a rule model and a control mechanism script of each object, wherein a model is established for the incidence relation between the operation of a person and equipment and products so as to reflect the influence of the operation of the person on the assembly process; the digital description of the assembly station is realized through the models, and finally, incidence relations and interaction relations are established for all the models.
3. The design method of the digital twin satellite pulsating assembly plant as claimed in claim 1, wherein the assembly plant digital twin model of step 1 comprises: the model covers various objects of a field, personnel, materials, equipment, tools and products of the final assembly workshop; firstly, constructing a final assembly workshop three-dimensional model, and on the basis of the assembly station three-dimensional model, constructing the final assembly workshop three-dimensional model together by designing and arranging the positions of all stations and combining the three-dimensional design of logistics distribution routes, logistics storage and product storage; secondly, designing a workshop communication network architecture based on a data interface of an assembly station, carrying out interface debugging and association on a data model of the assembly station, adding data models of products, logistics, processes and environments, and constructing and forming a data model of a final assembly workshop; then, constructing a logistics equipment motion model, a product quality model, a workshop operation and maintenance rule model, a workshop control mechanism script and a workshop environment model; the digital description of the final assembly workshop is realized through the models, and finally, the association relation and the interaction relation are established for all the models.
4. The design method of the digital twin satellite pulsating assembly workshop as claimed in claim 1, wherein the virtual-real interactive debugging of step 2 comprises: the developed model, the communication interface and the control mechanism script are communicated and debugged with the corresponding physical entity, the physical entity has the problem of self fault before being accessed into the module, the debugged physical entity is guaranteed to be reliable, meanwhile, the information communication is real-time and reliable, and the station and workshop digital twin model is verified under the excitation of the same signal, so that the consistency of the geometric dimension of the three-dimensional model, the motion behavior of the mechanical motion model, the data relation of the data model, the attribute characteristics of the physical attribute model, the rule and the boundary of the rule model and the actual station and equipment is ensured.
5. The design method of a digital twin satellite pulsating assembly workshop as claimed in claim 1, wherein the assembly staff model library of the step 3 comprises:
A. process mean time to completion prediction model PaThe system is used for predicting the completion time of different processes on an assembly station so as to assist in process propulsion, general assembly flow management, time prediction of logistics distribution and management and control strategy design;
B. process completion time prediction model P based on individual proficiencypFor making a time to completion prediction for a process that is partially dependent on the proficiency of an individual's manual work;
C. worker-station matching degree model P based on individual operation capacitymThe method is used for realizing station process distribution according to the skill characteristics of workers;
D. fatigue degree prediction model P based on individual body energyfThe method is used for predicting the fatigue of workers so as to realize the scheduling of the workers in the general assembly process and the process completion time prediction based on the scheduling.
6. The design method of the digital twin satellite pulsed assembly shop according to claim 1, wherein the multi-objective optimization algorithm-based assembly shop optimization of the step 4 comprises: performing multi-aspect simulation analysis on the final assembly process to judge whether design defects exist in station process execution, station layout, logistics distribution and workshop scheduling; aiming at design defects, the indexes to be optimized and related constraints are analyzed, mathematical expressions of a target function, an index function and a constraint function are established, a proper multi-objective optimization algorithm is selected, mathematical model conversion is carried out on the design model to form an algorithm available model, a corresponding optimal solution or a pareto optimal solution is formed through multi-objective optimization, and a general assembly shop design correction strategy is formed by combining engineering practical conditions.
7. The design method of the digital twin satellite pulsating assembly workshop as claimed in claim 1, wherein the digital twin system instantiation in the step 5 comprises:
A. the assembly workshop layout model comprises an assembly line scene layout diagram, an equipment layout diagram and a logistics path diagram and is used for guiding the construction of a field site and the construction of a digital twin satellite pulsating assembly workshop system model;
B. the network architecture scheme and the network interface script are used for guiding the construction of a field communication network, including network routing, interface configuration and protocol development;
C. the logistics control scheme and the logistics equipment control script are used for guiding the building of a logistics system, the establishment of a logistics strategy, the configuration of logistics equipment on the assembly site and the building of an assembly line MES system;
D. the station equipment automatic control scheme and the station equipment control script are used for guiding the formulation of an assembly line and a specific station control scheme and the system building of an assembly line MES system and a station MES subsystem;
E. the worker process task allocation is used for guiding site worker station allocation, process allocation and worker scheduling.
8. A digital twin satellite pulsating assembly shop design system, comprising:
A. a secondary packaging design module based on digital twin, which comprises a plurality of standardized model libraries, a model construction tool, a communication network design tool, a control logic design tool and a three-dimensional graphical interactive interface, supports the design and packaging of a model, a communication interface and a control mechanism of an assembly station, sets the position of the assembly station in a general assembly workshop, and designs and packages logistics logic, a logistics route and a control mechanism script of logistics equipment;
B. the digital twin virtual-real interactive debugging module accesses the physical entity and the virtual model into a system through a data interface to realize acquisition of homologous data of the physical entity and the virtual model, simultaneously comprises a process operation instruction library and an operation control instruction library, sends the same instruction as an excitation signal to the physical entity and the virtual model, verifies feedback output and difference value of the physical entity and the virtual model, and provides a correction suggestion for the virtual model exceeding an allowable threshold;
C. the general assembly worker model base is constructed according to historical operation data of general assembly field workers, can be called by other modules and is updated according to the accumulation degree of the historical data;
D. the process simulation analysis module converts the assembly work order into a simulation script, drives the simulation data by using real-time or historical data of equipment and real-time or historical operation records of personnel, simulates a network function, a station function, a logistics function and an entire line operation function of a final assembly design model by combining a final assembly worker model, verifies the production capacity of a final assembly workshop under different conditions and generates a simulation result; analyzing a simulation result, performing target function, index function, constraint function setting and multi-objective optimization algorithm selection on a model needing to be corrected and optimized, optimizing a design model and forming a correction strategy;
E. and the digital twin system instantiation module instantiates and outputs the final assembly workshop design model as a design scheme, the scheme comprises an assembly line scene layout diagram, a network architecture scheme, a network interface script, a logistics path diagram, a logistics control scheme, a logistics equipment control script, a station equipment automatic control scheme and a station equipment control script, and meanwhile, the final assembly workshop digital twin model and the assembly station digital twin model are beneficial to constructing the digital twin of the actual final assembly workshop.
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