CN112198812B - Simulation and control method and system of micro-assembly production line based on digital twinning - Google Patents
Simulation and control method and system of micro-assembly production line based on digital twinning Download PDFInfo
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Abstract
The invention discloses a simulation and control method and a system of a micro-assembly production line based on digital twins, relates to the technical field of micro-assembly, and solves the technical problems that the micro-assembly process cannot be monitored in real time and the micro-assembly product is not high in consistency. Then performing off-line simulation optimization on the micro-assembly process flow to obtain a micro-assembly scheme; the optimization guidance of off-line simulation optimization is realized, and the quality of the micro-assembly process flow design is improved. And finally, the digital twin model of the micro-assembly production line performs real-time synchronous mapping on the micro-assembly production process according to the real-time production data, so that the production data is visualized, the effective informatization management and control of the micro-assembly process equipment are realized, the monitoring capability of field workers on the micro-assembly process can be greatly improved, and the assembly quality of micro-assembly products is further improved.
Description
Technical Field
The disclosure relates to the technical field of micro-assembly, in particular to a simulation and control method and system of a micro-assembly production line based on digital twinning.
Background
The active phased array radar is used as a core sensing device of modern war, and the complexity and the integration level of the active phased array radar reach unprecedented height. In the phased array radar detection information flow, the core manufacturing technology of key core components is a micro-assembly technology, and the micro-assembly process has the characteristics of multiple varieties, variable batches, mixed line production, complex process, high product quality requirement and the like. At present, the manual, semi-automatic or automatic process equipment who separates is adopted to little equipment process more, mainly relies on the manual work, can't implement the equipment process of control product for the uniformity of product is relatively poor, and the through rate is lower, and product assembly quality is difficult to effectively improve. Meanwhile, due to the fact that effective informatization management cannot be carried out on a large number of micro-assembly process equipment and a large number of micro-assembly process equipment, reasonable configuration and effective utilization of equipment resources are difficult to achieve, and research, development and production progress are seriously affected. Therefore, when micro-assembling such products, real-time monitoring of the processing conditions of each intelligent device and timely solving of the problems occurring during the micro-assembling process to reduce the loss are the engineering problems to be solved urgently at present.
Nowadays, with the rapid development of new generation computer technologies such as internet of things, big data, cloud computing and the like, the intercommunication interconnection between the physical world and the information world is realized, a digital twin workshop concept is generated, an actual production process of a physical workshop is simulated mainly by means of a digital model equivalent to a physical entity, tasks such as process design, intelligent manufacturing unit scheduling and scheduling are developed based on a workshop digital model, intelligent manufacturing units are effectively integrated and controlled based on network interconnection and data sharing, information interaction and overall management among production links are realized, and therefore the purposes of effectively improving the product assembly quality and reducing the production cost are achieved.
At present, no digital twin synchronous simulation and control system for the micro-assembly field exists at home and abroad, and the proposed digital twin synchronous simulation and control system is mainly researched for the manufacturing of the fields of aerospace, automobiles, ships and the like, and has great difference with the application environment of the micro-assembly field. The intelligent micro-assembly technology is still in the germination stage, no unified standard and standard exist at present, and how to realize synchronous simulation and control of the micro-assembly production line through the digital twin technology is a problem to be solved urgently.
Disclosure of Invention
The invention provides a simulation and control method and a system of a micro-assembly production line based on digital twins, which aims to realize real-time monitoring of a micro-assembly process, realize reasonable configuration and effective utilization of equipment resources in the micro-assembly process and improve the consistency of products.
The technical purpose of the present disclosure is achieved by the following technical solutions:
a simulation and control method of a micro-assembly production line based on digital twinning comprises the following steps:
analyzing production elements in the micro-assembly process, constructing a geometric physical model through the production elements, constraining the geometric physical model through key information and rules in a physical layer, and combining the key information and the rules with the geometric physical model to obtain a digital twin model;
acquiring related information of the micro-assembly product from an off-line process file, adjusting and updating the digital twin model by using the related information, and reconstructing to obtain the digital twin model of the micro-assembly production line;
performing off-line simulation optimization on the micro-assembly process flow, and optimizing the micro-assembly process flow to obtain a micro-assembly scheme;
and producing according to the micro-assembly scheme, and carrying out real-time synchronous mapping on the micro-assembly production line by the digital twin model of the micro-assembly production line according to real-time production data.
Further, after the key information and the rules are fused with the geometric physical model, the digital twin model comprising four dimensions of geometric physics, attribute information, behavior logic and constraint rules is generated; the key information and rules in the physical layer include: basic attribute information of the physical entity, dynamic behavior logic of the physical entity and constraint rules of the micro-assembly process.
Further, adjusting and updating the digital twin model using the relevant information includes:
updating the geometric physics, the attribute information, the behavior logic and the constraint rule of the digital twin model into actual information of the micro-assembly product;
adding and forbidding production units of the digital twin model, and adjusting the layout relation of the digital twin model to obtain the digital twin model of the micro-assembly production line;
wherein the related information comprises of the micro-assembled product: the method comprises the following steps of process flow chart, loading pieces and auxiliary materials, process content and requirements, equipment tool information, working hour quota, processing parameter information and behavior logic information.
Further, the offline simulation optimization includes detecting command errors, interference errors and flow errors in the micro-assembly process, and specifically includes:
s1: judging the information specification format in the off-line process file, and if the information specification format meets the process file specification requirement of off-line simulation, turning to the step S2; if the process file specification requirements of off-line simulation are not met, giving an information position needing to be adjusted as a micro-assembly initial assembly scheme;
s2: extracting an instruction in the off-line process file, enabling a micro-assembly product to perform assembly motion according to a micro-assembly path, performing interference alarm detection on the assembly motion, pausing off-line simulation if the interference alarm occurs, recording an instruction row of the interference alarm, modifying the off-line process file according to error feedback information, and circulating the steps from S1 to S2 until the interference alarm does not occur in the micro-assembly process to obtain a micro-assembly scheme;
s3: after the off-line simulation is finished, comparing the micro-assembly scheme with a system rule, recording an instruction line which is not in accordance with the system rule, and carrying out optimization reminding on the micro-assembly scheme according to a judgment result; wherein the system rules include process rules, conflict rules, and decision rules.
A simulation and management control system of a micro-assembly production line based on digital twinning comprises:
the twin model modeling subsystem analyzes production elements in the micro-assembly process, constructs a geometric physical model through the production elements, constrains the geometric physical model through key information and rules in a physical layer, and combines the key information and rules with the geometric physical model to obtain a digital twin model;
the production line reconstruction subsystem acquires relevant information of the micro-assembly product from the off-line process file, adjusts and updates the digital twin model by using the relevant information, and reconstructs the digital twin model to obtain the micro-assembly production line digital twin model;
the off-line simulation subsystem is used for carrying out off-line simulation optimization on the micro-assembly process flow, optimizing the micro-assembly process flow and obtaining a micro-assembly scheme;
and the twin synchronization subsystem is used for producing according to the micro-assembly scheme, and the digital twin model of the micro-assembly production line is used for carrying out real-time synchronous mapping on the micro-assembly production line according to real-time production data.
Further, after the key information and the rules are fused with the geometric physical model, the digital twin model comprising four dimensions of geometric physics, attribute information, behavior logic and constraint rules is generated; the key information and rules in the physical layer include: basic attribute information of the physical entity, dynamic behavior logic of the physical entity and constraint rules of the micro-assembly process.
Further, the line modeling subsystem includes:
the updating module is used for updating the geometric physics, the attribute information, the behavior logic and the constraint rule of the digital twin model into the actual information of the micro-assembly product;
the adjusting module is used for performing adding and forbidding operations on the production units of the digital twin model, and adjusting the layout relation of the digital twin model to obtain the digital twin model of the micro-assembly production line;
wherein the related information comprises of: the method comprises the following steps of process flow chart, loading pieces and auxiliary materials, process content and requirements, equipment tool information, working hour quota, processing parameter information and behavior logic information.
Further, the offline simulation optimization includes detecting command errors, interference errors, and flow errors in the micro-assembly process, and the offline simulation subsystem specifically includes:
the judging module is used for judging the information specification format in the off-line process file, and if the information specification format meets the process file specification requirement of off-line simulation, the information specification format is transferred to the detecting module; if the process file specification requirements of off-line simulation are not met, giving an information position needing to be adjusted as a micro-assembly initial assembly scheme;
the detection module extracts the instruction in the off-line process file, enables the micro-assembly product to perform assembly motion according to a micro-assembly path, performs interference alarm detection on the assembly motion, suspends off-line simulation if the interference alarm occurs, records an instruction line of the interference alarm, modifies the off-line process file according to error feedback information, and circulates the steps from S1 to S2 until the interference alarm does not occur in the micro-assembly process to obtain a micro-assembly scheme;
the optimization module compares the micro-assembly scheme with a system rule after off-line simulation is finished, records an instruction line which is not in accordance with the system rule, and carries out optimization reminding on the micro-assembly scheme according to a judgment result; the system rules comprise process rules, conflict rules and decision rules.
The beneficial effect of this disclosure lies in: the simulation and control method and system of the micro assembly production line based on the digital twin, disclosed by the invention, analyze production elements of a micro assembly process, construct a geometric physical model through the production elements, and then constrain the geometric physical model through key information and rules in a physical layer to obtain a digital twin model; and acquiring related information of the micro-assembly product from an off-line process file, and adjusting and updating the digital twin model by using the related information to obtain the digital twin model of the micro-assembly production line. Then, performing off-line simulation optimization on the micro-assembly process flow, and optimizing the micro-assembly process flow to obtain a micro-assembly scheme; due to the data support of the related information of the micro-assembly product, the optimization and the knowledge of the off-line simulation optimization are realized, and the quality of the micro-assembly process flow design is improved.
And finally, production is carried out according to the micro-assembly scheme, the digital twin model of the micro-assembly production line carries out real-time synchronous mapping on the micro-assembly production line according to real-time production data, the visualization of the production data is realized, the effective informatization management and control of micro-assembly process equipment are realized, the monitoring capability of field workers on the micro-assembly process can be greatly improved, and the assembly quality of micro-assembly products is further improved.
Drawings
FIG. 1 is a flow chart of the disclosed method;
FIG. 2 is a schematic view of the disclosed system;
FIG. 3 is a schematic diagram of a digital twin model generation process, taking a cube as an example;
FIG. 4 is an optimization flow diagram for off-line simulation optimization;
FIG. 5 is a flow chart of twin synchronization.
Detailed Description
The technical scheme of the disclosure will be described in detail with reference to the accompanying drawings.
Fig. 1 is a flow chart of the method of the present disclosure, and as shown in fig. 1, a digital twin model is first constructed, production elements in a micro-assembly process are analyzed, a geometric physical model is constructed by implementing production elements of automation equipment, parts, components, etc. through computer aided design software, the geometric physical model is constrained through key information and rules in a physical layer, and the key information and rules in the physical layer are mapped to the geometric physical model, so as to obtain the digital twin model.
The key information and rules in the physical layer are physical entity basic attribute information, physical entity dynamic behavior logic in the micro-assembly process and micro-assembly process constraint rules specific to the micro-assembly process, and the key information and rules are fused with the geometric physical model to generate a digital twin model containing four dimensions of the geometric physics, the attribute information, the behavior logic and the constraint rules.
The geometric physical model comprises the geometric size, the spatial position and the constraint relation of the production elements in the physical workshop; the attribute information comprises basic information, configuration information and process attributes of the production elements in the physical workshop; the behavior logic comprises the kinematic logic and the kinematic algorithm of the production element in the physical workshop; the constraint rules comprise process constraint rules, production decision constraint rules and industry standard rules of the production elements in the production and processing process.
FIG. 3 is a schematic diagram of a digital twin model generation flow, taking a cube as an example, first selecting production elements in a micro-assembly process, taking the cube as an example, and performing geometric and physical dimension measurement by using intelligent digital measurement equipment; and then establishing a geometric physical model of the production element through computer aided design software, and adding attribute information, behavior logic and constraint rules to the geometric physical model to generate a digital twin model containing four dimensions of the geometric physics, the attribute information, the behavior logic and the constraint rules.
And after the digital twin model is constructed, generating the digital twin model of the micro-assembly production line. Acquiring relevant information of the micro-assembly product from the off-line process file, and adjusting and updating the digital twin model by using the relevant information so as to obtain the digital twin model of the micro-assembly production line; the information related to the micro-assembled product includes: the method comprises the following steps of a process flow chart, a loading part and auxiliary materials, process contents and requirements, equipment and tool information, working hour quota, processing parameter information and behavior logic information. And on the basis, according to the difference of equipment tools and processing parameters required by the assembly of different micro-assembled products and the moving path of the AGV logistics trolley, carrying out layout relation adjustment on the digital twin model and updating the corresponding equipment processing parameters to generate the digital twin model of the micro-assembled production line, which integrates the actual processing information of the micro-assembled products. The method comprises the following specific steps: (1) Updating the geometric physics, attribute information, behavior logic and constraint rules of the digital twin model into actual information of the micro-assembly product to obtain an updated digital twin model; (2) And adding and forbidding the production units of the updated digital twin model, and adjusting the layout relation of the digital twin model to obtain the digital twin model of the micro-assembly production line.
After the digital twin model of the micro-assembly production line is generated, off-line simulation optimization is carried out on the micro-assembly process flow, as shown in fig. 4, command errors, interference errors and flow errors in the micro-assembly process are detected, and optimization reminding is carried out on the processing scheme which does not accord with the system setting judgment rule. The method specifically comprises the following steps:
s1: judging the information specification format in the off-line process file, and if the information specification format meets the process file specification requirement of off-line simulation, turning to the step S2; if the process file specification requirements of off-line simulation are not met, giving an information position needing to be adjusted as a micro-assembly initial assembly scheme;
s2: extracting an instruction in the off-line process file, enabling the micro-assembly product to perform assembly motion according to a micro-assembly path, performing interference alarm detection on the assembly motion, pausing off-line simulation and highlighting an interference alarm part if the interference alarm occurs, recording an instruction line of the interference alarm, modifying the off-line process file according to error feedback information, and circulating the steps from S1 to S2 until the interference alarm does not occur in the micro-assembly process to obtain a micro-assembly scheme;
s3: after the off-line simulation is finished, comparing the micro-assembly scheme with the system rule, recording an instruction line which is not in accordance with the system rule, and carrying out optimization reminding on the micro-assembly scheme according to a judgment result; the system rules comprise process rules, conflict rules and decision rules.
After off-line simulation optimization, production is carried out according to an optimized micro-assembly scheme, a digital twin model of a micro-assembly production line carries out real-time synchronous mapping on the micro-assembly production line according to real-time production data, twin synchronous simulation in the micro-assembly process is realized, the production data is updated and displayed in real time, on-line monitoring is realized, corresponding alarm feedback is made according to the result of error reminding in the twin synchronous simulation process, accurate control of the micro-assembly process is realized, a flow chart of twin synchronous is shown in figure 5, the real-time production data is preprocessed after being collected, then the data is screened through models such as attribute information, behavior logic, constraint rules and the like, the data is synchronized through a geometric physical model and is stored in a database after being synchronized, and the database interacts with the production data collected in real time.
The display content of the real-time production data comprises the environmental temperature and the relative humidity of a physical workshop, the running state of each automated device, corresponding process parameters in the processing process of each automated device, the processing time of parts in a key process, the number of finished assemblies of different micro-assembled products and the product qualification rate information; the error alarm feedback reminding content comprises pose information error reporting, machine alarm and feedback signal missing.
The position and posture of the position and posture information reporting error indicating chip in the material box are different from the correct position and posture information, and for the error, the system highlights the chip model with the problem, sends a production line production stopping command and gives error feedback information; the machine alarm means that in the twin synchronization process, production equipment in a physical workshop is in an alarm state due to an accident condition, for the errors, the system suspends the twin synchronization simulation, displays a corresponding equipment state signal lamp as an alarm state, sends a production line stop production command and gives an equipment maintenance notice; the feedback signal loss means that twin synchronous simulation cannot be carried out due to scanning failure, data request failure and material loss, and for the errors, the system sends equipment maintenance notification, industrial Ethernet inspection notification and AGV material delivery notification according to the signal loss reasons.
Fig. 2 is a schematic diagram of the system of the present disclosure, which includes a twin model modeling subsystem, a production line modeling subsystem, an off-line simulation subsystem, and a twin synchronization subsystem, wherein the production line modeling subsystem further includes an updating module and an adjusting module, the off-line simulation subsystem includes a judging module, a detecting module, and an optimizing module, and specific functions of each module refer to the method of the present disclosure, and are not repeated.
In addition, the system can also comprise a user login subsystem and a data management subsystem, wherein the user login subsystem is used for carrying out user authority management on the system, and a user can login the system through a specific account password; the data management subsystem is used as a support for the operation of the off-line simulation subsystem and the twin synchronization subsystem, and is used for carrying out real-time data acquisition, analysis, classification and storage on parts/components/automation equipment in a physical workshop through an intelligent sensor and other intelligent acquisition equipment and carrying out corresponding processing on simulation data and related derivative data obtained in the simulation process.
The foregoing is illustrative of the embodiments of the present disclosure, and the scope of the present disclosure is defined by the claims and their equivalents.
Claims (4)
1. A simulation and control method of a micro-assembly production line based on a digital twin is characterized by comprising the following steps:
analyzing production elements in the micro-assembly process, constructing a geometric physical model through the production elements, constraining the geometric physical model through key information and rules in a physical layer, and combining the key information and the rules with the geometric physical model to obtain a digital twin model; the key information and rules in the physical layer are basic attribute information of the physical entity, dynamic behavior logic of the physical entity in the micro-assembly process and a micro-assembly process constraint rule specific to the micro-assembly process; the key information and the rules are fused with the geometric physical model, and a digital twin model containing four dimensions of geometric physics, attribute information, behavior logic and constraint rules is generated;
acquiring related information of a micro-assembly product from an off-line process file, adjusting and updating the digital twin model by using the related information, and reconstructing to obtain a digital twin model of a micro-assembly production line; wherein, the related information of the micro-assembly product comprises: the method comprises the following steps of (1) a process flow chart, a loading part and auxiliary materials, process contents and requirements, equipment tool information, a working hour quota, processing parameter information and behavior logic information;
performing off-line simulation optimization on the micro-assembly process flow, and optimizing the micro-assembly process flow to obtain a micro-assembly scheme;
producing according to the micro-assembly scheme, and carrying out real-time synchronous mapping on the micro-assembly production line by the digital twin model of the micro-assembly production line according to real-time production data;
the offline simulation optimization includes detecting command errors, interference errors and flow errors in the micro-assembly process, and specifically includes:
s1: judging the information specification format in the off-line process file, and if the information specification format meets the process file specification requirement of off-line simulation, turning to the step S2; if the process file specification requirements of off-line simulation are not met, giving an information position needing to be adjusted as a micro-assembly initial assembly scheme;
s2: extracting an instruction in the off-line process file, enabling the micro-assembly product to perform assembly motion according to a micro-assembly path, performing interference alarm detection on the assembly motion, pausing off-line simulation if the interference alarm occurs, recording an instruction row of the interference alarm, modifying the off-line process file according to error feedback information, and circulating the steps from S1 to S2 until the interference alarm does not occur in the micro-assembly process to obtain a micro-assembly scheme;
s3: after the off-line simulation is finished, comparing the micro-assembly scheme with a system rule, recording an instruction line which is not in accordance with the system rule, and carrying out optimization reminding on the micro-assembly scheme according to a judgment result; the system rules comprise process rules, conflict rules and decision rules.
2. The method for simulation and control of a digital twin-based micro assembly line as set forth in claim 1, wherein the adjusting and updating of the digital twin model using the relevant information comprises:
updating the geometric physics, the attribute information, the behavior logic and the constraint rule of the digital twin model into actual information of the micro-assembly product;
and adding and forbidding the production units of the digital twin model, and adjusting the layout relation of the digital twin model to obtain the digital twin model of the micro-assembly production line.
3. A simulation and management control system of a micro-assembly production line based on digital twinning is characterized by comprising the following components:
the twin model modeling subsystem analyzes production elements in the micro-assembly process, constructs a geometric physical model through the production elements, constrains the geometric physical model through key information and rules in a physical layer, and combines the key information and rules with the geometric physical model to obtain a digital twin model; the key information and rules in the physical layer are basic attribute information of the physical entity, dynamic behavior logic of the physical entity in the micro-assembly process and a micro-assembly process constraint rule specific to the micro-assembly process; the key information and the rules are fused with the geometric physical model, and a digital twin model containing four dimensions of geometric physics, attribute information, behavior logic and constraint rules is generated;
the production line reconstruction subsystem acquires relevant information of the micro-assembly product from the off-line process file, adjusts and updates the digital twin model by using the relevant information, and reconstructs the digital twin model to obtain the micro-assembly production line; wherein the related information of the micro-assembly product comprises: the method comprises the following steps of (1) a process flow chart, a loading part and auxiliary materials, process contents and requirements, equipment tool information, working hour quota, processing parameter information and behavior logic information;
the off-line simulation subsystem is used for carrying out off-line simulation optimization on the micro-assembly process flow, optimizing the micro-assembly process flow and obtaining a micro-assembly scheme;
the twin synchronization subsystem is used for producing according to the micro-assembly scheme, and the digital twin model of the micro-assembly production line is used for carrying out real-time synchronous mapping on the micro-assembly production line according to real-time production data;
the offline simulation optimization includes detecting command errors, interference errors and flow errors in a micro-assembly process, and the offline simulation subsystem specifically includes:
the judging module is used for judging the information standard format in the off-line process file, and if the information standard format meets the process file standard requirement of off-line simulation, the information standard format is transferred to the detecting module; if the process file specification requirement of the off-line simulation is not met, giving an information position needing to be adjusted as a micro-assembly initial assembly scheme;
the detection module extracts the instruction in the off-line process file, enables the micro-assembly product to perform assembly motion according to a micro-assembly path, performs interference alarm detection on the assembly motion, suspends off-line simulation if the interference alarm occurs, records an instruction line of the interference alarm, modifies the off-line process file according to error feedback information, and circulates the steps from S1 to S2 until the interference alarm does not occur in the micro-assembly process to obtain a micro-assembly scheme;
the optimization module compares the micro-assembly scheme with a system rule after off-line simulation is finished, records an instruction line which is not in accordance with the system rule, and performs optimization reminding on the micro-assembly scheme according to a judgment result; wherein the system rules include process rules, conflict rules, and decision rules.
4. The simulation and control system of a digital twin-based micro-assembly production line as set forth in claim 3, wherein the production line reconfiguration sub-system comprises:
the updating module is used for updating the geometric physics, the attribute information, the behavior logic and the constraint rule of the digital twin model into the actual information of the micro-assembly product;
and the adjusting module is used for performing adding and forbidding operations on the production units of the digital twin model and adjusting the layout relation of the digital twin model to obtain the digital twin model of the micro-assembly production line.
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