CN112241579A - Virtual simulation system and method for steel production process - Google Patents
Virtual simulation system and method for steel production process Download PDFInfo
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Abstract
The invention provides a virtual simulation system and a virtual simulation method for a steel production process, wherein a virtual model is subjected to roaming observation and roaming rate adjustment through human-computer interaction to construct a three-dimensional scene; receiving production plan data, and preprocessing the production plan data to obtain production data to be executed; receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction; and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction. The game engine is applied to the process industrial simulation system, is visual and vivid, effectively solves the problems of non-visual and poor information integrity and effectiveness in the traditional information expression mode, outputs various simulation results, displays the production state and evaluates the quality of a plan.
Description
Technical Field
The invention relates to the technical field of computer simulation, in particular to a virtual simulation system and method for a steel production process, which are applied to the technical field of auxiliary control systems for the production process of a digital steel plant.
Background
Because the steel production capacity in China is excessive, the way that enterprises obtain the cost advantage by enlarging the economic scale is not feasible any more; and the new technology which can greatly improve the productivity and reduce the consumption in the steel industry is more difficult to obtain. Under the condition, the cost advantage is acquired, and the iron and steel enterprises need to control and reduce the cost of each link of production, sales and logistics through lean management and control of the production process under a stable market scale.
With the development of simulation technology and new requirements of manufacturing industry, the simulation technology has been further expanded to logistics supply, inventory management, organization of product development process, product testing, etc., involving various aspects of manufacturing enterprises. Particularly in the aspect of supply chain management, logistics simulation is becoming a commonly adopted technology for enterprises to improve the lean production management level. However, the mainstream simulation display systems in the market generally have the problems of poor image quality effect, low response speed, lack of human-computer interaction, complex system construction and the like.
The Unreal engine is one of the most popular engines in the world for developing third party games. UE4(Unreal Engine 4) is a C + + based new-generation open-source free development tool released by EpicGames company, and is a set of complete game development framework prepared for DirectX10/11PC, Xbox One, Android and other platforms. The method has the advantages of high rendering efficiency, vivid physical properties, seamless connection with various three-dimensional graphics software and the like, is mainly used in the field of game development at first, and can well simulate physical phenomena in the real world by virtue of a powerful physical engine and a powerful particle system, so that the method is not limited to the field of game development, has good application value in the fields of industrial system simulation, building visualization and the like, but does not see relevant reports about the application of the method to steel production process management. In order to solve the series of problems, a 3D game engine-based solution is needed, and a steel production process virtual simulation system which is strong in interactivity, smoother and vivid is built.
The prior art related to the present application is that patent document CN106295198A relates to the field of medical education and training, in particular to a standardized patient system based on VR virtual reality technology; the standardized patient system comprises a VR virtualized standard patient, a virtual standardized patient library module connected with the VR virtualized standard patient, a VR 720-degree panoramic virtual scene library module and various disease examination data and image data modules; the virtual reality technology is utilized to establish a simulated standardized patient, and the intelligent operation control is carried out on the simulated person through the control of system software programming, thereby realizing the clinical diagnosis process.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a virtual simulation system and method for a steel production process.
The invention provides a virtual simulation system for a steel production process, which comprises:
a scene roaming module: switching and zooming the virtual model in all directions, and performing roaming observation and roaming rate adjustment on the virtual model through human-computer interaction to construct a three-dimensional scene;
a plan input module: receiving production plan data, and preprocessing the production plan data to obtain production data to be executed;
a plan execution module: receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction;
a simulation evaluation module: and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction.
Preferably, the plan input module includes:
the information input module: receiving production plan information input by a process control computer or a person, and collecting actual production information which reflects the production information of the unit materials in each process in real time;
a data processing module: and managing actual production information by combining with production plan information, converting and decomposing to obtain production demand information, and generating production data to be executed by combining with production specification requirements, wherein the production data to be executed comprises a production plan.
Preferably, the plan execution module includes:
starting a model: starting and operating a model program for carrying out animation simulation on the steel production process, carrying out animation simulation operation and flow simulation operation, and analyzing and executing a production plan of production data;
starting an engine: starting and operating a virtual engine to drive a virtual model in a three-dimensional scene to move by data;
demonstration production steps: and simulating the steel production process by using the blueprint visual script and the action instruction of the illusion engine to perform animation demonstration on the steel production process.
Preferably, the steel production process virtual simulation system further comprises a plan management module, and the plan management module corrects the production data to be executed according to the equipment specification requirement in the production process and the real-time running state information in the production process so as to meet the raw material individuation requirement.
Preferably, the steel production process virtual simulation system further comprises a material tracking module, which is used for performing unified updating and maintenance on process material information in the production process, collecting and processing the process material information in the production process in real time to form a tracking record, and reflecting the production state and the material state of each process in the production process in real time.
The virtual simulation method for the steel production process provided by the invention comprises the following steps:
scene roaming step: switching and zooming the virtual model in all directions, and performing roaming observation and roaming rate adjustment on the virtual model through human-computer interaction to construct a three-dimensional scene;
plan input step: receiving production plan data, and preprocessing the production plan data to obtain production data to be executed;
planning and executing steps: receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction;
a simulation evaluation step: and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction.
Preferably, the plan input step includes:
information entry step: receiving production plan information input by a process control computer or a person, and collecting actual production information which reflects the production information of the unit materials in each process in real time;
and (3) data processing: and managing actual production information by combining with production plan information, converting and decomposing to obtain production demand information, and generating production data to be executed by combining with production specification requirements, wherein the production data to be executed comprises a production plan.
Preferably, the plan executing step includes:
starting a model: starting and operating a model program for carrying out animation simulation on the steel production process, carrying out animation simulation operation and flow simulation operation, and analyzing and executing a production plan of production data;
starting an engine: starting and operating a virtual engine to drive a virtual model in a three-dimensional scene to move by data;
demonstration production steps: and simulating the steel production process by using the blueprint visual script and the action instruction of the illusion engine to perform animation demonstration on the steel production process.
Preferably, the virtual simulation method for the steel production process further comprises a plan management step, wherein production data to be executed are corrected according to the equipment specification requirement in the production process and the real-time running state information in the production process so as to meet the raw material personalized requirement.
Preferably, the steel production process virtual simulation method further comprises a material tracking step, wherein the process material information in the production process is updated and maintained in a unified manner, and is collected and processed in real time to form a tracking record, so that the production state and the material state of each process in the production process are reflected in real time.
Compared with the prior art, the invention has the following beneficial effects:
1. the virtual simulation system for the steel production process is provided, and the steel production process is visually simulated by using the technical scheme of virtual simulation.
2. The system can dynamically simulate the steel production line, respond to user instructions and the like in real time, enable the computer to track the input of the user, modify the virtual environment obtained by simulation in time according to the input and establish a real-time interactive relationship between the user and the simulated environment.
3. The lean management and control capability of resource management and production technology is improved, the consumption is effectively reduced, the production cost is reduced, and the productivity can be greatly improved.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a system framework diagram of one embodiment of the present invention.
Fig. 2 is a schematic workflow diagram of an embodiment of the present invention.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
The invention provides a virtual simulation system for a steel production process, which comprises:
a scene roaming module: switching and zooming the virtual model in all directions, and performing roaming observation and roaming rate adjustment on the virtual model through human-computer interaction to construct a three-dimensional scene;
a plan input module: receiving production plan data, and preprocessing the production plan data to obtain production data to be executed;
a plan execution module: receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction;
a simulation evaluation module: and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction.
Specifically, the plan input module includes:
the information input module: receiving production plan information input by a process control computer or a person, and collecting actual production information which reflects the production information of the unit materials in each process in real time;
a data processing module: and managing actual production information by combining with production plan information, converting and decomposing to obtain production demand information, and generating production data to be executed by combining with production specification requirements, wherein the production data to be executed comprises a production plan.
Specifically, the plan execution module includes:
starting a model: starting and operating a model program for carrying out animation simulation on the steel production process, carrying out animation simulation operation and flow simulation operation, and analyzing and executing a production plan of production data;
starting an engine: starting and operating a virtual engine to drive a virtual model in a three-dimensional scene to move by data;
demonstration production steps: and simulating the steel production process by using the blueprint visual script and the action instruction of the illusion engine to perform animation demonstration on the steel production process.
Specifically, the steel production process virtual simulation system further comprises a plan management module, and the plan management module corrects production data to be executed according to the equipment specification requirement in the production process and the real-time running state information in the production process so as to meet the raw material individuation requirement.
Specifically, the steel production process virtual simulation system further comprises a material tracking module, wherein the material tracking module is used for uniformly updating and maintaining process material information in the production process, collecting and processing the process material information in the production process in real time to form a tracking record, and reflecting the production state and the material state of each process in the production process in real time.
The virtual simulation method for the steel production process provided by the invention comprises the following steps:
scene roaming step: switching and zooming the virtual model in all directions, and performing roaming observation and roaming rate adjustment on the virtual model through human-computer interaction to construct a three-dimensional scene;
plan input step: receiving production plan data, and preprocessing the production plan data to obtain production data to be executed;
planning and executing steps: receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction;
a simulation evaluation step: and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction.
Specifically, the plan input step includes:
information entry step: receiving production plan information input by a process control computer or a person, and collecting actual production information which reflects the production information of the unit materials in each process in real time;
and (3) data processing: and managing actual production information by combining with production plan information, converting and decomposing to obtain production demand information, and generating production data to be executed by combining with production specification requirements, wherein the production data to be executed comprises a production plan.
Specifically, the plan executing step includes:
starting a model: starting and operating a model program for carrying out animation simulation on the steel production process, carrying out animation simulation operation and flow simulation operation, and analyzing and executing a production plan of production data;
starting an engine: starting and operating a virtual engine to drive a virtual model in a three-dimensional scene to move by data;
demonstration production steps: and simulating the steel production process by using the blueprint visual script and the action instruction of the illusion engine to perform animation demonstration on the steel production process.
Specifically, the virtual simulation method for the steel production process further comprises a plan management step, wherein production data to be executed are corrected according to the equipment specification requirement in the production process and the real-time running state information in the production process so as to meet the raw material individuation requirement.
Specifically, the steel production process virtual simulation method further comprises a material tracking step, wherein the process material information in the production process is updated and maintained in a unified mode, and is collected and processed in real time to form a tracking record, and the production state and the material state of each process in the production process are reflected in real time.
The virtual simulation system for the steel production process can be realized by the step flow of the virtual simulation method for the steel production process. The person skilled in the art can understand the steel production process virtual simulation method as a preferred example of the steel production process virtual simulation system.
In specific implementation, as shown in fig. 1, a virtual simulation system for a steel production process mainly comprises a series of control units of a scene roaming subsystem, a plan input subsystem, a plan execution subsystem and a simulation evaluation subsystem, and forms a whole system framework with a 4-layer structure of a database layer, a phantom engine service layer, an application layer and a presentation layer;
the database layer stores key data of the system through a file set and mainly comprises a scene database and a service database, wherein metadata of the scene database mainly comprises model, material and action data, and metadata of the service database mainly comprises coordinates and production information of steel production process equipment and running logic data of the system, and comprises data information of amplification and reduction, rotational translation, visual angle conversion and action triggering of the steel production process model;
the unreal engine service layer can analyze, load and input dynamic data into the plan execution subsystem, and drive the three-dimensional model by using the data, thereby realizing the visual output of the steel production process of the steel production workshop; the Spawn node in the blueprint system of the Unreal engine is utilized to create a virtual model required on a steel-making production line, the Unreal engine is a fully integrated professional three-dimensional engine, a light and shadow rendering system and a particle system with soft shadow and baking and high perfection are provided, the engine has the advantages that the technical requirements of the development process are high, the advanced rendering effect and the user customization support are far higher than those of other advantages, and the requirements of virtual display and vivid representation are very suitable; the application layer comprises a scene roaming subsystem, a plan input subsystem and a simulation evaluation subsystem, and is mainly used for realizing data acquisition, data file preprocessing, data interaction operation, 2D and 3D roaming navigation, animation simulation expression in the steel production process, real-time presentation of the steel production process and equipment state information, output of the simulation result in the steel production process and evaluation of the simulation result in the steel production process according to different steel production plans; the presentation layer comprises a user interface module of a man-machine interaction subsystem and a special effect processing module of a three-dimensional model generation subsystem;
the application layer mainly comprises a scene roaming subsystem, a plan input subsystem and a simulation evaluation subsystem, and is mainly used for realizing data acquisition, data file preprocessing, data interaction operation, 2D and 3D roaming navigation, animation simulation expression in the steel production process, real-time presentation of the steel production process and equipment state information, output of the simulation result in the steel production process and evaluation of the simulation result in the steel production process according to different steel production plans;
the presentation layer mainly comprises a user interface module of a human-computer interaction subsystem;
the control units of the whole system are specifically as follows:
the scene roaming subsystem can carry out omnibearing visual angle switching and scaling on each virtual model of the system, two forms of movement of a 2D aerial view angle and a 3D first-person visual angle are supported, a user can realize scene roaming observation of any direction of the virtual models of the steel production line through the human-computer interaction subsystem, and can adjust roaming rate through the human-computer interaction subsystem;
the plan input subsystem can compile and optimize a production plan in the steel production and logistics processes, manually input steel production plan data by a user through the man-machine interaction subsystem and transmit the steel production plan data to the plan execution subsystem, and also dynamically import steel production plan data dynamically imported by an external server to the plan execution subsystem, support the connection with a database, dynamically import data and preprocess data files;
the plan execution subsystem starts and runs a model program for carrying out animation simulation on the whole steel production process according to an input or imported data format, carries out animation simulation operation and flow simulation operation, analyzes and executes a corresponding steel production plan, starts and runs a phantom engine, drives the motion of a virtual model in a three-dimensional scene by data, simulates the steel production process by using a blueprint visual script code and an action system of the phantom engine, and carries out animation demonstration on the steel production process through the human-computer interaction subsystem.
The simulation evaluation subsystem is updated in real time, the state information of each device of the steel production process can be displayed and output in real time through the human-computer interaction subsystem, the simulation result of the steel production process can be evaluated and compared according to different steel production plans input by the plan input subsystem, the better scheme and the best scheme of the steel production process optimization can be obtained through analysis, example application data resources in the database layer can be called, the suggestion of the steel production process optimization is obtained, the simulation operation condition information and the simulation evaluation result are displayed and output in real time through the human-computer interaction subsystem, and a user makes a decision according to the evaluation index corresponding to the simulation evaluation result.
In the database layer, preferably, the metadata of the business database mainly includes data information of enlargement and reduction, rotational translation, view angle conversion and action triggering of the steel production process model.
A virtual simulation system for the steel production process is constructed by adopting a phantom engine, and comprises the following steps:
step 1: establishing an equipment model and a scene model for steel production, performing equivalent modeling on a steel production workshop by using MAYA to obtain an equivalent three-dimensional model of a virtual space, and outputting a 3D format file in an OBJ or FBX format;
step 2: making and rendering a mapping material by using MAYA software and Photoshop software, and making and rendering the mapping material by using the material of a real equipment model adopted in the steel production process as reference;
and step 3: importing an equipment model and building a scene, importing the FBX and OBJ format files output in the step 1 into a phantom engine, and building a steel production line model according to the layout of a steel production workshop and the requirements of a process flow;
and 4, step 4: performing expression treatment on an optical effect and a particle effect, wherein the process from steel casting to plate blank rolling is the main steel production process flow of steel making, and the visual simulation and illumination rendering of the flowing of the system fluid are realized by using a particle system and a light source system of an illusion engine according to the movement of the fluid and the lighting effect of a scene in the real steel production process;
and 5: and establishing an information connection logical relationship of the system function modules, so that the scene roaming subsystem, the plan input subsystem, the plan execution subsystem and the simulation evaluation subsystem form a virtual simulation system in the whole steel production process.
The moving speed of the scene roaming subsystem is adjusted by a sliding bar form of the engine UMG functional module, and the roaming part supports the switching of different visual angles of each steel production equipment model and also supports information interaction in a keyboard input mode.
The scene roaming subsystem can realize virtual human roaming in a virtual scene, can perform viewpoint switching, collision detection and terrain tracking, can acquire target information, can perform zooming, rotation and translation of the scene, can adjust illumination, sound and animation, and can perform event perception.
The plan input subsystem can input a steel-making plan, a steel ladle transfer plan, a casting order plan, a continuous casting plan, a slab warehouse-in and warehouse-out plan, a furnace charging plan, warehouse-transferring operation plan data, a hot rolling production plan and order information of a steel-making area.
The steelmaking plan which can be input by the plan input subsystem mainly comprises a slab cutting plan and relevant information of slab flow direction, the hot rolling plan comprises a furnace charging plan, a hot rolling batch plan/unit plan slab sequence plan, a hot rolling coil finishing plan and relevant information of hot rolling coil/slab flow direction, and the hot rolling production plan comprises a hot rolling coil/slab warehousing plan, a transfer plan and a delivery plan.
The plan input subsystem mainly collects actual production information from a process control computer (or manual input), reflects the output information of unit materials in each process in real time, is used for knowing the production condition of a virtual steel plant workshop and monitoring the production process so as to improve the efficiency and quality of processing activities. Meanwhile, the collected production data is effectively managed, and other functional modules have requirements for reading actual data. According to the amount of the contract required to be produced, steel marks and rolling specifications can be separated, and the amount of the contract plate blank required to be applied can be summarized and displayed. The application amount of the contract plate blank can be converted and decomposed into a virtual plate blank number, and a steelmaking heat and continuous casting pouring time plan is formed according to the requirements of the same steel tapping mark and the same section specification.
The plan execution module can start and run a model program which is generated by the three-dimensional model generation subsystem and used for carrying out animation simulation on the whole steel production process according to an input or imported data format, carry out animation simulation operation and flow simulation operation, analyze and execute a corresponding steel production plan, start and run an illusion engine, drive the motion of a virtual model in a three-dimensional scene by data, simulate the steel production process by using blueprint visualization script codes and an action system of the illusion engine, and carry out animation demonstration on the steel production process through the human-computer interaction subsystem.
The simulation evaluation subsystem can feed back warning error events occurring in the simulation operation in real time, and can at least display and output the utilization rate of steel production equipment and the station waiting time information through the human-computer interaction subsystem. The simulation evaluation module can feed back warning error events occurring in simulation operation in real time; when the simulation evaluation module initializes the virtual simulation environment, the initial states of a steel-making production line, a slab library, a hot-rolling production line and a hot-rolling finished product library at the simulation starting moment are initialized; when the simulation of the steelmaking-continuous casting production process is carried out in the simulation evaluation module, based on the steelmaking-continuous casting production line simulation environment, a steelmaking plan is taken as an input condition, the execution process of each plan in the steelmaking-continuous casting stage is simulated in a three-dimensional virtual mode, and a simulation observation value is output, wherein the simulation observation value mainly comprises the simulation actual process of the smelting process of molten steel of each heat on each process device and the transmission of the actual process information of the molten steel among the processes; when simulation of a slab library is carried out in a simulation evaluation module, based on a slab library simulation environment, taking a slab warehousing plan, a transfer plan, a delivery plan and a charging sequence plan as input conditions, simulating an execution process of slab logistics in the slab library, and outputting a simulation observation value, wherein the simulation observation value mainly comprises process simulation actual information of slab warehousing operation, transfer operation, sorting and stack reversing, charging operation and the like; when the simulation evaluation module simulates the hot rolling production process, the execution process of each plan in the hot rolling production stage is simulated by taking the hot rolling plan as an input condition based on the simulation environment of a hot rolling production line, and simulation observation values are output, wherein the simulation observation values comprise the processing starting time and the processing finishing time information of each slab/steel coil in each hot rolling stage.
Preferably, when the virtual simulation environment is initialized in the simulation evaluation subsystem, the initial states of the steel-making production line, the slab library, the hot rolling production line and the hot rolling finished product library at the simulation starting moment are initialized, the states change along with the simulation process, the steel-making production line initialization mainly comprises the states, the capabilities and the inter-process transfer time of steel-making-continuous casting production line equipment, the slab library initialization mainly comprises the states, the capabilities, the empty/full-load operation speed and slab stacking rules of the slab library, the hot rolling production line initialization mainly comprises the states and the capabilities of the hot rolling production line equipment, and the hot rolling finished product library initialization mainly comprises the initialization of the states, the capabilities, the operation speed and the hot rolling stacking rule information of the hot rolling finished product library equipment; when the simulation of the steelmaking-continuous casting production process is carried out in the simulation evaluation subsystem, based on the steelmaking-continuous casting production line simulation environment, the execution process of each plan in the steelmaking-continuous casting stage is simulated in a three-dimensional virtual mode by taking a steelmaking plan as an input condition, and a simulation observation value is output, wherein the simulation observation value mainly comprises the simulation actual performance of the smelting process of molten steel on each process device of each furnace and the information of the actual performance of the process of the molten steel transmitted among the processes; when slab library simulation is carried out in the simulation evaluation subsystem, based on a slab library simulation environment, taking a slab warehousing plan, a transfer plan, a delivery plan and a charging sequence plan as input conditions, simulating an execution process of slab logistics in the slab library, and outputting a simulation observation value, wherein the simulation observation value mainly comprises process simulation actual performance information of slab warehousing operation, transfer operation, sorting and stack reversing, charging operation and the like; when the simulation evaluation subsystem simulates the hot rolling production process, the execution process of each plan in the hot rolling production stage is simulated by taking the hot rolling plan as an input condition based on the simulation environment of a hot rolling production line, and simulation observation values are output, wherein the simulation observation values comprise the processing starting time and the processing finishing time information of each slab/steel coil in each hot rolling stage.
In specific implementation, the overall system will also be divided into two types of monitoring functions: 1. the process parameters of the machine set which are not related to the large category of products carry out real-time trend monitoring and conformity statistics on the corresponding process parameter requirements according to the machine set, the process section and the process parameters, alarm or prompt is carried out when the key parameters exceed the range, and related analysis and handling are carried out on trend abnormity; 2. real-time trend monitoring and conformity statistics are carried out by combining the requirements of corresponding process parameters of key products, alarming or prompting is carried out when the key parameters exceed the range, and relevant analysis and treatment are carried out on trend abnormity.
In a preferred embodiment, the virtual simulation system in the steel production process adopts a C/S architecture-based cross-operating system platform design based on a ghost engine technology, is divided into 4-layer structures of a database layer, a ghost engine service layer, an application layer and a presentation layer, and adopts a series of simulation system core modules according to the characteristics of the steel production process; the database stores key data of the system through a file set, and is divided into a scene database and a service database in a platform, wherein metadata of the scene database comprises modeling, materials and actions, and metadata of the service database comprises coordinates and production information of steel production process equipment, mainly refers to operation logic of the system, and comprises data information of model enlargement and reduction, rotation and translation, visual angle conversion and action triggering. The presentation layer includes a user interface and special effects processing including animation effects and model special effects. The illusion engine analyzes dynamic data from the MES system, and drives the equivalent three-dimensional model by using the data, thereby realizing the purpose of visualizing the steel production workshop. The control part adds a control interface and a production plan operation interface in the visual interface, and a user can issue a production plan execution command through the interfaces and send the command to each control unit in the system. According to the method, through research on the intelligent manufacturing workshop, the state information of production planning and scheduling of the MES system is used for driving a model in a three-dimensional virtual space, namely an equivalent three-dimensional model of the virtual space, so that the state of the manufacturing workshop is simulated by using three-dimensional animation, and the workshop state is displayed in the virtual space, so that the production process is visually represented, production bottleneck factors are found in time, and decision making is guided.
Referring to fig. 1, the moving speed of the scene roaming subsystem is adjusted by the sliding bar of the engine UMG functional module, and the roaming part supports the switching of different viewing angles of each steel production equipment model and also supports information interaction through a keyboard input mode. The scene roaming subsystem can realize virtual human roaming in a virtual scene, can perform viewpoint switching, collision detection and terrain tracking, can acquire target information, can perform zooming, rotation and translation of the scene, can adjust illumination, sound and animation, and can perform event perception.
The plan input subsystem can input a steel-making plan, a steel ladle transfer plan, a casting order plan, a continuous casting plan, a slab warehouse-in and warehouse-out plan, a furnace charging plan, warehouse-transferring operation plan data, a hot rolling production plan and order information of a steel-making area. The steelmaking plan which can be input by the plan input subsystem specifically comprises a slab cutting plan and relevant information of slab flow direction, the hot rolling plan comprises a furnace charging plan, a hot rolling batch plan/unit plan slab sequence plan, a hot rolling coil finishing plan and relevant information of hot rolling coil/slab flow direction, the hot rolling production plan comprises a hot coil/slab warehousing plan, a transfer plan and a delivery plan, and the order information comprises contract delivery date and other information. The plan input subsystem supports connections with the database, enabling dynamic import of data. All plans related to production and logistics processes which need to be executed in a simulation period provide effective guarantee for the operation effect of the simulation evaluation subsystem.
When the virtual simulation environment initialization is carried out in the simulation evaluation subsystem, the initial states of a steel-making production line, a slab bank, a hot rolling production line and a hot rolling finished product bank at the simulation starting moment are initialized, the states change along with the simulation process, the steel-making production line initialization mainly comprises the states, the capabilities and the inter-process transfer time of steel-making-continuous casting production line equipment, the slab bank initialization mainly comprises the states, the capabilities, the empty/full-load running speeds and slab stacking rules of slab banks, the hot rolling production line initialization mainly comprises the states and the capabilities of hot rolling production line equipment, the hot rolling finished product bank initialization mainly comprises the initialization of the states, the capabilities, the running speeds and the hot rolling stacking rule information of the hot rolling finished product bank equipment, wherein the steel-making-continuous casting production line equipment comprises smelting equipment and transportation equipment, the hot rolling production line equipment, A finishing mill group, laminar cooling and a crimping machine; when the simulation of the steelmaking-continuous casting production process is carried out in the simulation evaluation subsystem, three-dimensionally and virtually simulating the execution process of each plan in the steelmaking-continuous casting stage based on the steelmaking-continuous casting production line simulation environment and taking a steelmaking plan as an input condition, and outputting simulation observation values, wherein the simulation observation values comprise the smelting process simulation actual results of molten steel of each heat on each process device and the process actual result information transmitted by the molten steel among the processes; when slab library simulation is carried out in the simulation evaluation subsystem, based on a slab library simulation environment, taking a slab warehousing plan, a transfer plan, a delivery plan and a charging sequence plan as input conditions, simulating an execution process of slab logistics in the slab library, and outputting a simulation observation value, wherein the simulation observation value mainly comprises process simulation actual performance information of slab warehousing operation, transfer operation, sorting and stack reversing, charging operation and the like; when the simulation evaluation subsystem simulates the hot rolling production process, the execution process of each plan in the hot rolling production stage is simulated by taking the hot rolling plan as an input condition based on the simulation environment of a hot rolling production line, and simulation observation values are output, wherein the simulation observation values comprise the processing starting time and the processing finishing time information of each slab/steel coil in each hot rolling stage.
In an embodiment, referring to fig. 1 and 2, the plan execution subsystem parses and executes the corresponding plan according to the input or imported data format to data-drive the motion of the virtual model in the three-dimensional scene to simulate the production reality. The steel production process is demonstrated in an animation mode by using blueprint visual script codes and an action system of the illusion engine, so that the steel production process simulation system can be applied to steel production process assisting and is possible to be applied to steel production process control. The virtual simulation evaluation subsystem of the embodiment updates and displays the state information of each device in real time according to the simulation running condition, outputs a plan evaluation result and feeds back warning error events occurring in the simulation running in time. In the running process of the model, the utilization rate of equipment and the station waiting time can be displayed, and the evaluation indexes can prompt operators how to make decisions so that the indexes can better meet the actual needs and the production efficiency is improved.
In an embodiment, referring to fig. 1 and 2, a multi-functional operating platform is integrated, the design of which is organized in a modular way. The virtual simulation system is a three-dimensional virtual simulation system for simulating a real steel production line, can dynamically simulate the steel production line, makes real-time response to user instructions and the like, modifies the simulated virtual environment in time according to input, simulates the whole process of the steel production line by animation, and evaluates and feeds back the quality result of a production plan. In the real-time simulation process, a user can modify parameters in the current layout scheme, the simulation system can display a new operation condition according to the modified parameters and observe a new system operation result, and the user can be helped to further evaluate the scheme. In the simulation operation process, different parts of the operation scene can be browsed through the forms of direction keys, shortcut keys, menus and the like, and detailed simulation analysis can be performed on the parts. The production plan input subsystem can realize the compilation and optimization of production plans such as heat, casting times, hot rolling and the like, a user can manually input production plan data and can also dynamically import the production plan data from a server, and the operation control scheme is very rich. The production plan execution subsystem can analyze and execute a corresponding plan according to an input or imported data format so as to drive the motion of a virtual model in a three-dimensional scene through data and simulate production reality. The blueprint visualization script codes and the action system of the illusion engine are utilized to demonstrate the steel production flow in an animation mode, and the effect is vivid. The simulation system evaluation subsystem can update and display the state information of each device in real time according to the simulation running condition, output the evaluation result and feed back warning error events occurring in the simulation running in time. The utilization rate of equipment, the station waiting time and the like can be displayed, the evaluation indexes can prompt an operator how to make a decision, so that the indexes can better meet the actual needs, and the production efficiency is improved.
In a preferred example, the simulation evaluation subsystem can feed back warning error events occurring in the simulation operation in real time, and can display and output the utilization rate and station waiting time information of the steel production equipment through the human-computer interaction module. In the same virtual environment, due to the interaction of users and the movement of objects, collision problems can be involved between models or between elements inside the models, at the moment, in order to maintain the reality of the environment, the collisions need to be detected in time, corresponding collision reactions are calculated, and drawing results are updated, otherwise, the objects can penetrate through, and the reality of the virtual environment and the immersion of the users are damaged. Therefore, in order to increase the sense of reality of virtual roaming, the collision detection function is also realized, so that collision early warning of models such as slabs and crown blocks is prompted in time.
The invention integrates the most important function modules of the traditional MES system, abandons some functions with lower practical value of the prior simulation system, mainly collects the actual production information input by a process control computer or manual work, reflects the output information of the unit materials in each process in real time, is used for knowing the production condition of a workshop and monitoring the production process so as to improve the efficiency and the quality of the processing activities. Meanwhile, the collected production data is effectively managed, and other functional modules have requirements for reading actual performance data.
The management of the pre-planning of continuous casting is mainly the management of the manufacturing order for the rational production of the continuous casting machine. The data includes information such as a manufacturing command number, a steel grade, a tapping mark, a refining path, a pouring date, a size of a cast slab, and the like. Manufacturing commands used in steel making and continuous casting production are divided into a heat manufacturing command and a casting blank manufacturing command. The heat production command is a command used in a process such as a converter and secondary refining in units of furnaces.
In the invention, the specification size of the virtual material in the forming manufacturing command has a manual correction function so as to meet the special requirements of the steel rolling on the raw material. In order to improve the productivity of steel making, the steel making furnace frequency plan can be organized according to various slab widths for the same production plan under the condition that the pressure of the slab width expanding side in the steel rolling process is allowed.
The casting schedule of one machine or multiple streams can be organized according to the type of the continuous casting machine, and the casting schedule has the functions of correcting and checking the casting section and the furnace weight. The material application can support the compilation of a cold charging plan, a heat preservation pit hot charging plan and a DHCR direct hot charging plan corresponding to the hot charging requirement, ensure that the cutting sequence of the slab can adapt to the charging sequence (or rolling sequence) requirement of the slab, and reduce slab unstacking operation. The material application plan has a query display function, and the heat can be searched from the casting time and the virtual plate blank can be searched from the heat; and has a history simulation information query function. The method has the capability of sectionally configuring the virtual material number, the manufacturing command number and the casting number of continuous casting. The system has the capability of managing and inquiring the yield or non-yield of the slabs.
In the hot rolling operation plan, a function of editing a hot rolling region process operation plan and an operation command in a man-machine combination manner is provided, the hot rolling operation plan comprises hot rolling (heating and rolling), hot coil finishing and hot coil packaging operation plan compiling and editing, and finally, a process operation plan which is in accordance with process operation regulations, ordered, executable and favorable for logistics balance is formed. .
The material tracking and performance management is to uniformly update and maintain the information of raw materials, products in process and finished products in the hot rolling range, such as adding/modifying/deleting/managing blocking/managing releasing of materials. The material information comprises basic information, quality information, contract information, operation plan information, stock position information and the like of the material, meanwhile, the material tracking and actual performance management collects and processes actual performance information of production from a lower computer of each production unit in real time, provides production record tracking from raw materials to finished products, and reflects the specific production state and material state information of each process of a system factory in real time.
In the invention, the material management basic module is used for supporting the material data requirements of other related PES systems and other internal modules, so that the virtual simulation system can be used for the production organization of the whole hot rolling process. The material management also considers that the material information is logged in, modified and deleted in a man-machine conversation mode under special conditions.
The actual performance management has the main function of collecting and processing corresponding production actual performance data of processing information, quality technological parameters, packaging information, blocking release information and the like of materials on each production unit in real time. The actual performance management module carries out instant processing on various collected data according to triggering of production actual performance information of each unit, and the actual performance management module reflects main information in actual performance on data and states of materials produced by each unit, wherein the main information includes material processing information, packaging information, energy consumption information and the like, so that a user can monitor the production condition and the production process of the materials, and the efficiency and the quality of processing activities are improved.
The material tracking function mainly tracks the material in the whole process in the processing process so as to know the processing condition, the size and weight change condition, the process quality condition and the like in the production simulation process; meanwhile, the production actual performance of each unit in the hot rolling range, the detailed information of the produced materials, the production process record information of the produced materials, and output reports such as class/daily reports can be inquired.
In fact, steelmaking-continuous casting-hot rolling is a key part and bottleneck process of the steel production process, and in the steelmaking-continuous casting-hot rolling production process, a plurality of unpredictable abnormal events exist, and in the actual production process, the abnormal events are generally dynamically processed by a scheduling staff. However, how to achieve the effect of satisfying the manual intervention in the actual production process needs to achieve the dynamic adjustment function in the simulation system, and when the operation result of the simulation system does not accord with the production plan, the related rules can be called to dynamically adjust the production plan, thereby ensuring the smooth and orderly production. The dynamic adjustment is generally managed based on rules and models, and how to apply relevant rules and models to the virtual simulation system distinguishing the traditional MES system is a big problem in realizing the system of the invention.
On the basis of a self-contained three-dimensional simulation scene picture, a functional model integrates main information types related to MES system software, and the MES system software has objects such as equipment, materials, process segments, production capacity, product information, production plans, production performance and the like which are mainly considered by conventional MES system software, and adopts a general information technical standard to realize an information exchange mechanism and an information exchange mode; the service logic standard defines the functional composition of the system and the mutual relation among the functional modules in detail, and MES system software of other manufacturers can realize standard integration as long as the functional relation and the data interface relation defined by the standard are met when the integration with the system is realized.
The virtual scene is firstly drawn by a three-dimensional model, and the three-dimensional modeling technology is the most important technical field in 3D simulation. Three-dimensional modeling techniques have existed as an important technique for 3D simulation for many years, but because the amount of computer computation and data generation is too large in implementing three-dimensional scenes, the requirements on computers are high, especially for implementing high-quality three-dimensional scenes. Although this is an effective method, a high-grade computer needs a large amount of investment and is not affordable by general users, such as using a graphic workstation with high calculation speed, large storage capacity and strong graphic function. Therefore, how to process the complex geometric model by using a middle-level computer, especially a microcomputer, is also one of the key problems to be solved by the present invention, which is to seek to solve the problems of processing, storing, transmitting and drawing of the complex model more effectively. Therefore, how to realize the real-time dynamic display of the model on the premise of meeting the reality of the image is also a difficulty to be overcome by the method, and has significant meaning for the auxiliary control of the steel production. The system simulates the real situation of a steel production field, can be zoomed and watched at any angle in a three-dimensional space, and has strong intuition; by utilizing the system, the plan can be placed in the system to run once before the production plan is actually put into production, so that the production bottleneck can be found in time, and the decision can be assisted; the system applies the game engine to a process industrial simulation system, is visual and vivid, and does not apply the technology at present in the steel industry; the system adopts a three-dimensional virtual simulation system, is different from various tables and curves in the traditional two-dimensional panel, and effectively solves the problems of non-intuition, poor information integrity and poor effectiveness in the traditional information expression mode; the simulation system can input and execute various plans, output various simulation results, display production states and evaluate the quality of the plans.
Those skilled in the art will appreciate that, in addition to implementing the systems, apparatus, and various modules thereof provided by the present invention in purely computer readable program code, the same procedures can be implemented entirely by logically programming method steps such that the systems, apparatus, and various modules thereof are provided in the form of logic gates, switches, application specific integrated circuits, programmable logic controllers, embedded microcontrollers and the like. Therefore, the system, the device and the modules thereof provided by the present invention can be considered as a hardware component, and the modules included in the system, the device and the modules thereof for implementing various programs can also be considered as structures in the hardware component; modules for performing various functions may also be considered to be both software programs for performing the methods and structures within hardware components.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (10)
1. A steel production process virtual simulation system is characterized by comprising:
a scene roaming module: switching and zooming the virtual model in all directions, and performing roaming observation and roaming rate adjustment on the virtual model through human-computer interaction to construct a three-dimensional scene;
a plan input module: receiving production plan data, and preprocessing the production plan data to obtain production data to be executed;
a plan execution module: receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction;
a simulation evaluation module: and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction.
2. The steel production process virtual simulation system of claim 1, wherein the plan input module comprises:
the information input module: receiving production plan information input by a process control computer or a person, and collecting actual production information which reflects the production information of the unit materials in each process in real time;
a data processing module: and managing actual production information by combining with production plan information, converting and decomposing to obtain production demand information, and generating production data to be executed by combining with production specification requirements, wherein the production data to be executed comprises a production plan.
3. The steel production process virtual simulation system according to claim 1, wherein the plan execution module comprises:
starting a model: starting and operating a model program for carrying out animation simulation on the steel production process, carrying out animation simulation operation and flow simulation operation, and analyzing and executing a production plan of production data;
starting an engine: starting and operating a virtual engine to drive a virtual model in a three-dimensional scene to move by data;
demonstration production steps: and simulating the steel production process by using the blueprint visual script and the action instruction of the illusion engine to perform animation demonstration on the steel production process.
4. The steel production process virtual simulation system of claim 1, further comprising a plan management module that corrects production data to be executed according to equipment specification requirements in the production process and real-time running state information in the production process to meet raw material personalization requirements.
5. The steel production process virtual simulation system of claim 1, further comprising a material tracking module for performing unified update and maintenance on process material information in the production process, collecting and processing the process material information in the production process in real time to form a tracking record, and reflecting the production state and the material state of each process in the production process in real time.
6. A virtual simulation method for a steel production process is characterized by comprising the following steps:
scene roaming step: switching and zooming the virtual model in all directions, and performing roaming observation and roaming rate adjustment on the virtual model through human-computer interaction to construct a three-dimensional scene;
plan input step: receiving production plan data, and preprocessing the production plan data to obtain production data to be executed;
planning and executing steps: receiving production data to be executed, starting and operating a simulation model program and a phantom engine, simulating a production process according to the production data to be executed, and demonstrating the production process through man-machine interaction;
a simulation evaluation step: and displaying the running state information in the production process in real time, evaluating a process simulation result formed by the production plan data, obtaining an optimization suggestion in the production process through evaluation, and displaying the evaluation and optimization suggestion through human-computer interaction.
7. The steel production process virtual simulation method according to claim 6, wherein the plan input step includes:
information entry step: receiving production plan information input by a process control computer or a person, and collecting actual production information which reflects the production information of the unit materials in each process in real time;
and (3) data processing: and managing actual production information by combining with production plan information, converting and decomposing to obtain production demand information, and generating production data to be executed by combining with production specification requirements, wherein the production data to be executed comprises a production plan.
8. The steel production process virtual simulation method according to claim 6, wherein the plan execution step includes:
starting a model: starting and operating a model program for carrying out animation simulation on the steel production process, carrying out animation simulation operation and flow simulation operation, and analyzing and executing a production plan of production data;
starting an engine: starting and operating a virtual engine to drive a virtual model in a three-dimensional scene to move by data;
demonstration production steps: and simulating the steel production process by using the blueprint visual script and the action instruction of the illusion engine to perform animation demonstration on the steel production process.
9. The steel production process virtual simulation method according to claim 6, further comprising a plan management step of correcting production data to be executed according to the equipment specification requirement in the production process and the real-time running state information in the production process so as to meet the raw material personalization requirement.
10. The steel production process virtual simulation method according to claim 6, further comprising a material tracking step of performing unified update maintenance on process material information in the production process, collecting and processing the process material information in the production process in real time to form a tracking record, and reflecting the production state and the material state of each process in the production process in real time.
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