CN114415607A - Design process manufacturing integrated digital twin system based on data driving - Google Patents
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Abstract
The invention discloses a data-driven integrated digital twin system for designing and manufacturing a process, which belongs to the technical field of process manufacturing, wherein a twin digital model is established to enable entity equipment to drive the twin digital model to cooperatively move with the entity equipment, the twin digital model drives the entity equipment to cooperatively move with the entity equipment, the purpose of bidirectional cooperative motion is realized, the working condition of the entity equipment is effectively simulated, large data is collected according to the production logic relation by collecting production data to form an integrated management system, the whole process is completed by monitoring the production data in real time and simulating each system of a workshop, the system automatically gives a workshop working guidance suggestion by analyzing and monitoring the simulated data, the difference value calculation is carried out on the real-time data and a standard database in the management system, and finally an emergency plan is generated by the correlation matching of the calculation result and hidden danger time, the phenomenon of accident detention is avoided, and the potential safety hazard of production is reduced.
Description
Technical Field
The invention belongs to the technical field of process manufacturing, and particularly relates to a data-driven design process manufacturing integrated digital twin system.
Background
The intelligent manufacturing not only provides a foundation and a condition for the military chess deduction of enterprise production operation management, but also provides a foundation and a condition for the military chess deduction of enterprise strategy management, because the intelligent manufacturing has the following management characteristics: firstly, intelligent manufacturing is a product of deep fusion of Internet, big data, artificial intelligence and advanced manufacturing technology, and a manufacturing mode revolution of digital Lisheng driving is formed; secondly, intelligent manufacturing based on digital twins forms the synergy of scale economy and range economy, so that the problem of duality of efficiency and flexibility in manufacturing management is solved to a new height; finally, based on intelligent manufacturing, the manufacturing industry can really realize management innovation facing user requirements, so that a user-driven management change 21 in a practical sense rather than a theoretical sense is formed, and therefore, the intelligent manufacturing can provide different scene analysis for enterprise strategic management and simulation optimization of production operation.
The digital twin is a simulation process integrating multidisciplinary, multi-physical quantity, multi-scale and multi-probability by fully utilizing data such as a physical model, sensor updating, operation history and the like, and mapping is completed in a virtual space, so that the full life cycle process of corresponding entity equipment is reflected. The digital twin is an beyond-reality concept, can be regarded as a digital mapping system of one or more important equipment systems which are dependent on each other, is a generally-adapted theoretical technical system, can be applied in a plurality of fields, and is more applied in the fields of product design, product manufacturing, medical analysis, engineering construction and the like. The most deep application in China is in the field of engineering construction, the highest attention and the hottest research are in the field of intelligent manufacturing.
The digital twins, the digital twins technology, originate from the mirror image of the aircraft in the Apollo project by the United states State aerospace agency, and are applied in the monitoring of the flight state. The general electric company implements a digital twin body on a cloud platform of the general electric company, adopts advanced technologies such as big data, Internet of things and the like to realize real-time monitoring, timely inspection and predictive maintenance of an engine, and sometimes is used for indicating a factory building and a production line of a factory to complete a digital model before the factory building is not carried out. Thus, the plant is simulated and simulated in the virtual Saybook space, and the real parameters are transmitted to the actual plant construction. After the workshops and the production lines are built, the workshops and the production lines continue to carry out information interaction in daily operation and maintenance, and the digital twin technology as a breakthrough technology provides great impetus for the realization of the technology, and the technology is possible to change the appearance of the manufacturing industry of today and the future. The digital twin, as a mirror of the real world, provides a means to simulate, predict, and optimize physical manufacturing systems and processes. The digital twin and intelligent algorithm can be used for realizing the operation monitoring and optimization of data driving, developing innovative products and services, improving the processing efficiency and ensuring the processing quality. Although research has reported potential application prospects of digital twins in the manufacturing industry, the current method for realizing digital twins in the manufacturing field lacks deep knowledge of concepts, frameworks and development methods of digital twins, and hinders the development of the application of digital twins in intelligent manufacturing.
In the process flow based on discrete production type enterprise processing production, most of the monitoring and management information systems of factory production processes are dedicated, single systems can only independently achieve designated functions, effective linkage among the systems is lacked, the systems cannot be effectively associated when accidents occur, the emergency plan is implemented by means of manual judgment, a series of emergency situations are difficult to deal with, the accidents are prone to being detained, the potential safety hazard of production is improved, and therefore the problem of designing, manufacturing and manufacturing of the integrated digital twin system based on data driving is needed.
Disclosure of Invention
Technical problem to be solved
In order to overcome the defects in the prior art, the invention provides a data-driven design process-based integrated digital twin system, and solves the problems that a single system can only independently achieve an appointed function, effective linkage is lacked among the systems, the systems cannot be effectively associated when an accident occurs, an emergency plan is implemented by means of manual judgment, a series of emergency situations are difficult to deal with, the accident is easy to be delayed, and the potential safety hazard of production is improved.
(II) technical scheme
In order to achieve the purpose, the invention provides the following technical scheme: the integrated digital twin system manufactured based on the data-driven design process comprises a physical entity unit, wherein the physical entity unit comprises a sensing module, a data acquisition module and a GPS positioning module, the sensing module, the data acquisition module and the GPS positioning module are used for constructing a three-dimensional model of entity equipment, the three-dimensional model of the entity equipment is communicated with a through pipe communication module, and the output end of the physical entity unit is connected with the input end of a digital twin platform.
The output end of the digital twin platform is connected with the input end of the data analysis unit, the data analysis unit is in bidirectional connection with the data repository, the data repository is in bidirectional connection with the digital twin platform, the output end of the digital twin platform is connected with the input end of the management terminal, and the input end of the management terminal is connected with the input end of the data analysis unit.
As a further scheme of the invention: the sensing module comprises a temperature and humidity sensing module, a time sensing module, a pressure sensing module, a speed sensing module and a flow sensing module.
The data acquisition module comprises production comprehensive data, plan scheduling data, equipment parameter data, production quality associated data, material management data and production process data.
As a further scheme of the invention: the communication module comprises a network transmission channel and a communication module.
Network transmission channel: and the transmission protocols of local area networks, LANs, WiFi, Zigbee and 5G are supported.
A communication module: the system comprises a network route, a data communication interface, a man-machine interaction interface and a cloud database access port.
And accessing each physical resource through network and interface standardization, virtualizing the physical resources into resource nodes in the network so as to realize ubiquitous interconnection of physical entity information in a production workshop and perform interactive mapping with a virtual space.
As a further scheme of the invention: the construction steps of the three-dimensional model of the solid equipment are as follows.
And S10, acquiring device entity data information including design parameter information and production process parameter information of the entity device through the physical entity unit.
S11, constructing a multi-resolution map engine, simulating each production process link, establishing initial models of various entity devices by adopting 3Dmax/maya, determining physical data of the entity devices, bringing parameter information of each entity device and production process parameter information into the initial models to obtain three-dimensional models of the entity devices, wherein the physical attributes comprise temperature and humidity data information, time data information, pressure data information, speed data information and flow data information.
As a further scheme of the invention: in the step S11, the three-dimensional model production process simulation is matched with the map engine to obtain the region thumbnails of each production process, and a single process link in the three-dimensional model is selected to locate the three-dimensional scene of a specific process.
As a further scheme of the invention: the digital twin platform comprises a twin digital model, a removing module, a rendering module, a remote monitoring module and a PLC control module, and the twin digital model is established by the following steps.
And S20, inputting the parameter information of the current entity equipment and the parameter information of the production process into a twin system, confirming the time, the motion track, the pressure of equipment components, the process temperature and humidity environment information, the running speed of the equipment components and the transmission flow required by each parameter adjustment and each process of the entity equipment, and creating a twin digital model containing real-time data of each process in the twin system.
S21, adopting a Unreal engine as a bottom layer rendering engine, adopting a PBR technology to carry out material design on process equipment, rendering each process link in the twin digital model, adopting a rendering thread mechanism, executing program logic and rendering content in parallel, and distinguishing the position and motion track of each process component of the twin digital model.
And S22, controlling the digital twin platform through the PLC control module, enabling the entity device data to drive the twin digital model and the entity device to cooperatively move, enabling the twin digital model to drive the entity device to cooperatively move with the entity device, achieving the purpose of bidirectional cooperative movement, and remotely monitoring the entity device by adopting the remote monitoring module.
As a further scheme of the invention: in the step S20, the parameter information of the equipment and the parameter information of the production process are recorded into the twin digital model, and the eliminating module is used to retain the component information including the process motion in the three-dimensional model of the physical equipment and to remove the auxiliary components that do not participate in the process steps.
As a further scheme of the invention: the data analysis unit comprises a difference value calculation module, an association matching module and a strategy generation module;
a difference value calculation module: the method is used for calculating the difference value between the monitored real-time data and the standard database of the management system, and comprises the following specific calculation steps:
control data of each process about product quality characteristics is acquired, a quality characteristic value standard deviation is calculated and an average value X is taken, the quality characteristic value standard deviation is represented by S, the number of the acquired processes is k, the process control data is represented by a, and quality characteristic index values are represented by a1, b1, a.
An association matching module: the system is used for correlating and matching the standard deviation (S1.. S2.. Sk) of each process quality characteristic value with index information in a management system standard database to form normal matrix distribution, so that the (S1.. S2.. Sk) corresponds to one or more of (a 1, b 1.. and bn).
A policy generation module: the emergency plan generating system is used for matching the associated plan adjusting strategies in the management system standard database according to the corresponding index information [ a1, b1,. ] and bn ], generating emergency plans and feeding back data information to the management terminal in time.
As a further scheme of the invention: the data repository includes a historical data repository and a management system standard database.
Management system standard database: the system is used for inputting product quality characteristic control data and corresponding index data thereof, and associating corresponding plan adjusting strategies through different characteristic control data.
(III) advantageous effects
Compared with the prior art, the invention has the beneficial effects that:
1. according to the invention, the twin digital model is established to enable the entity equipment data to drive the twin digital model to cooperatively move with the entity equipment, the twin digital model drives the entity equipment to cooperatively move with the entity equipment, the purpose of bidirectional cooperative movement is realized, the working condition of the entity equipment is effectively simulated, the production data is collected, the big data is summarized according to the production logic relationship to form an integrated management system, all systems in a simulation workshop complete the whole process by monitoring the production data in real time, the system automatically gives a workshop working guidance suggestion by analyzing and monitoring the simulated data, the difference value calculation is carried out on the real-time data and a standard database in the management system, the emergency plan is generated by the correlation and matching of the calculation result and the hidden danger time, the accident retention phenomenon is avoided, and the production safety hidden danger is reduced.
2. In the invention, a three-dimensional model of entity equipment is established, a multi-resolution map engine is established, each production process link is simulated, the three-dimensional model production process simulation is matched with the map engine to obtain a regional thumbnail of each production process, and a single process link in the three-dimensional model can be positioned to a specific process three-dimensional scene, so that the checking and finishing of the three-dimensional model structure by personnel are facilitated.
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FIG. 1 is a schematic view of the structure of the present invention.
Detailed Description
The technical solution of the present patent will be described in further detail with reference to the following embodiments.
As shown in the figure, the present invention provides a technical solution: the integrated digital twin system manufactured based on the data-driven design process comprises a physical entity unit, wherein the physical entity unit comprises a sensing module, a data acquisition module and a GPS positioning module, the sensing module, the data acquisition module and the GPS positioning module are used for constructing a three-dimensional model of entity equipment, the three-dimensional model of the entity equipment is communicated with a through pipe communication module, and the output end of the physical entity unit is connected with the input end of a digital twin platform.
The output end of the digital twin platform is connected with the input end of the data analysis unit, the data analysis unit is bidirectionally connected with the data repository, the data repository is bidirectionally connected with the digital twin platform, the output end of the digital twin platform is connected with the input end of the management terminal, and the input end of the management terminal is connected with the input end of the data analysis unit.
The sensing module comprises a temperature and humidity sensing module, a time sensing module, a pressure sensing module, a speed sensing module and a flow sensing module.
The data acquisition module comprises production comprehensive data, plan scheduling data, equipment parameter data, production quality associated data, material management data and production process data.
The communication module comprises a network transmission channel and a communication module.
Network transmission channel: and the transmission protocols of local area networks, LANs, WiFi, Zigbee and 5G are supported.
A communication module: the system comprises a network route, a data communication interface, a man-machine interaction interface and a cloud database access port.
And accessing each physical resource through network and interface standardization, virtualizing the physical resources into resource nodes in the network so as to realize ubiquitous interconnection of physical entity information in a production workshop and perform interactive mapping with a virtual space.
The steps of constructing the three-dimensional model of the physical device are as follows.
And S10, acquiring device entity data information including design parameter information and production process parameter information of the entity device through the physical entity unit.
S11, constructing a multi-resolution map engine, simulating each production process link, establishing initial models of various entity devices by adopting 3Dmax/maya, determining physical data of the entity devices, bringing parameter information of each entity device and production process parameter information into the initial models to obtain three-dimensional models of the entity devices, wherein the physical attributes comprise temperature and humidity data information, time data information, pressure data information, speed data information and flow data information.
And S11, matching the three-dimensional model production process simulation with a map engine to obtain the region thumbnail of each production process, and selecting a single process link in the three-dimensional model to position to a specific process three-dimensional scene.
The digital twin platform comprises a twin digital model, a removing module, a rendering module, a remote monitoring module and a PLC control module, and the twin digital model is established by the following steps.
And S20, inputting the parameter information of the current entity equipment and the parameter information of the production process into a twin system, confirming the time, the motion track, the pressure of equipment components, the process temperature and humidity environment information, the running speed of the equipment components and the transmission flow required by each parameter adjustment and each process of the entity equipment, and creating a twin digital model containing real-time data of each process in the twin system.
S21, adopting a Unreal engine as a bottom layer rendering engine, adopting a PBR technology to carry out material design on process equipment, rendering each process link in the twin digital model, adopting a rendering thread mechanism, executing program logic and rendering content in parallel, and distinguishing the position and motion track of each process component of the twin digital model.
And S22, controlling the digital twin platform through the PLC control module, enabling the entity device data to drive the twin digital model and the entity device to cooperatively move, enabling the twin digital model to drive the entity device to cooperatively move with the entity device, achieving the purpose of bidirectional cooperative movement, and remotely monitoring the entity device by adopting the remote monitoring module.
In S20, the parameter information of the equipment and the parameter information of the production process are recorded into the twin digital model process, and the eliminating module is used for reserving the component information containing process motion in the three-dimensional model of the entity equipment and removing auxiliary components which do not participate in the process steps.
The data analysis unit comprises a difference value calculation module, an association matching module and a strategy generation module;
a difference value calculation module: the method is used for calculating the difference value between the monitored real-time data and the standard database of the management system, and comprises the following specific calculation steps:
control data of each process about product quality characteristics is acquired, a quality characteristic value standard deviation is calculated and an average value X is taken, the quality characteristic value standard deviation is represented by S, the number of the acquired processes is k, the process control data is represented by a, and quality characteristic index values are represented by a1, b1, a.
An association matching module: the system is used for correlating and matching the standard deviation (S1.. S2.. Sk) of each process quality characteristic value with index information in a management system standard database to form normal matrix distribution, so that the (S1.. S2.. Sk) corresponds to one or more of (a 1, b 1.. and bn).
A policy generation module: the emergency plan generating system is used for matching the associated plan adjusting strategies in the management system standard database according to the corresponding index information [ a1, b1,. ] and bn ], generating emergency plans and feeding back data information to the management terminal in time.
The data repository comprises a historical data repository and a management system standard database.
Management system standard database: the system is used for inputting product quality characteristic control data and corresponding index data thereof, and associating corresponding plan adjusting strategies through different characteristic control data.
In conclusion, the following results are obtained:
the method comprises the steps of establishing a twin digital model, enabling entity equipment data to drive the twin digital model to cooperatively move with entity equipment, enabling the twin digital model to drive the entity equipment to cooperatively move with the entity equipment, achieving the purpose of bidirectional cooperative movement, effectively simulating the working condition of the entity equipment, collecting big data according to a production logic relation through the collection of production data to form an integrated management system, simulating all systems of a workshop to complete a whole set of flow through the real-time monitoring of the production data, automatically giving a workshop working guidance suggestion through the analysis and monitoring of the simulated data, carrying out difference value calculation on the real-time data and a standard database in the management system, finally carrying out emergency plan generation through the correlation and matching of calculation results and hidden danger time, avoiding accident retention and reducing production safety hidden dangers.
The method comprises the steps of establishing a three-dimensional model of entity equipment, establishing a multi-resolution map engine, simulating each production process link, matching the three-dimensional model production process simulation with the map engine, obtaining area thumbnails of each production process, selecting a single process link in the three-dimensional model to be positioned to a specific process three-dimensional scene, facilitating checking and finishing of a three-dimensional model structure by personnel, and in the twin digital model establishing process, a removing module is used for keeping component information containing process movement in the three-dimensional model of the entity equipment, removing auxiliary components not participating in the process steps, reducing the quantity of the twin digital model, improving the virtual debugging speed, rendering each process link in the twin digital model, and further improving the three-dimensional simulation effect and the service performance of the twin system.
Although the preferred embodiments of the present patent have been described in detail, the present patent is not limited to the above embodiments, and various changes can be made without departing from the spirit of the present patent within the knowledge of those skilled in the art.
Claims (9)
1. The integrated digital twin system manufactured based on the data-driven design process comprises physical entity units and is characterized in that: the physical entity unit comprises a sensing module, a data acquisition module and a GPS positioning module, the sensing module, the data acquisition module and the GPS positioning module are used for constructing a three-dimensional model of entity equipment, the three-dimensional model through pipe communication module of the entity equipment carries out information transmission, and the output end of the physical entity unit is connected with the input end of the digital twin platform;
the output end of the digital twin platform is connected with the input end of the data analysis unit, the data analysis unit is in bidirectional connection with the data repository, the data repository is in bidirectional connection with the digital twin platform, the output end of the digital twin platform is connected with the input end of the management terminal, and the input end of the management terminal is connected with the input end of the data analysis unit.
2. The data-driven based design process manufacturing integrated digital twinning system of claim 1, wherein: the sensing module comprises a temperature and humidity sensing module, a time sensing module, a pressure sensing module, a speed sensing module and a flow sensing module;
the data acquisition module comprises production comprehensive data, plan scheduling data, equipment parameter data, production quality associated data, material management data and production process data.
3. The data-driven based design process manufacturing integrated digital twinning system of claim 2, wherein: the communication module comprises a network transmission channel and a communication module;
network transmission channel: the transmission protocols of local area networks, LANs, WiFi, Zigbee and 5G are supported;
a communication module: the system comprises a network route, a data communication interface, a man-machine interaction interface and a cloud database access port;
and accessing each physical resource through network and interface standardization, virtualizing the physical resources into resource nodes in the network so as to realize ubiquitous interconnection of physical entity information in a production workshop and perform interactive mapping with a virtual space.
4. The data-driven based design process manufacturing integrated digital twinning system of claim 3, wherein: the construction steps of the three-dimensional model of the entity equipment are as follows;
s10, acquiring device entity data information including design parameter information and production process parameter information of the entity device through a physical entity unit;
s11, constructing a multi-resolution map engine, simulating each production process link, establishing initial models of various entity devices by adopting 3Dmax/maya, determining physical data of the entity devices, bringing parameter information of each entity device and production process parameter information into the initial models to obtain three-dimensional models of the entity devices, wherein the physical attributes comprise temperature and humidity data information, time data information, pressure data information, speed data information and flow data information.
5. The data-driven based design process manufacturing integrated digital twinning system of claim 4, wherein: in the step S11, the three-dimensional model production process simulation is matched with the map engine to obtain the region thumbnails of each production process, and a single process link in the three-dimensional model is selected to locate the three-dimensional scene of a specific process.
6. The data-driven based design process manufacturing integrated digital twinning system of claim 5, wherein: the digital twin platform comprises a twin digital model, a removing module, a rendering module, a remote monitoring module and a PLC control module, wherein the twin digital model is established by the following steps;
s20, inputting parameter information of each current entity device and parameter information of a production process into a twin system, confirming time, motion trail, device component pressure, process temperature and humidity environment information, device component running speed and transmission flow required by each parameter adjustment and each process of the entity device, and creating a twin digital model containing real-time data of each process in the twin system;
s21, adopting an Unreal engine as a bottom layer rendering engine, adopting a PBR technology to design the material of process equipment, rendering each process link in the twin digital model, adopting a rendering thread mechanism to execute program logic and rendering content in parallel, and distinguishing the position and motion track of each process component of the twin digital model;
and S22, controlling the digital twin platform through the PLC control module, enabling the entity device data to drive the twin digital model and the entity device to cooperatively move, enabling the twin digital model to drive the entity device to cooperatively move with the entity device, achieving the purpose of bidirectional cooperative movement, and remotely monitoring the entity device by adopting the remote monitoring module.
7. The data-driven based design process manufacturing integrated digital twinning system of claim 6, wherein: in the step S20, the parameter information of the equipment and the parameter information of the production process are recorded into the twin digital model, and the eliminating module is used to retain the component information including the process motion in the three-dimensional model of the physical equipment and to remove the auxiliary components that do not participate in the process steps.
8. The data-driven based design process manufacturing integrated digital twinning system of claim 7, wherein: the data analysis unit comprises a difference value calculation module, an association matching module and a strategy generation module;
a difference value calculation module: the method is used for calculating the difference value between the monitored real-time data and the standard database of the management system, and comprises the following specific calculation steps:
acquiring control data of each process about product quality characteristics, calculating a standard deviation of a quality characteristic value and taking an average value X, wherein the standard deviation of the quality characteristic value is represented by S, the number of the acquired processes is k, the process control data is represented by a, and quality characteristic index values are represented by a1, b1,. once.and bn;
an association matching module: the system is used for correlating and matching standard deviation (S1.. S2.. Sk) of each process quality characteristic value with index information in a management system standard database to form normal matrix distribution, so that the (S1.. S2.. Sk) corresponds to one or more of (a 1, b 1.. and bn);
a policy generation module: the emergency plan generating system is used for matching the associated plan adjusting strategies in the management system standard database according to the corresponding index information [ a1, b1,. ] and bn ], generating emergency plans and feeding back data information to the management terminal in time.
9. The data-driven based design process manufacturing integrated digital twinning system of claim 1, wherein: the data repository comprises a historical data repository and a management system standard database;
management system standard database: the system is used for inputting product quality characteristic control data and corresponding index data thereof, and associating corresponding plan adjusting strategies through different characteristic control data.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115469594A (en) * | 2022-09-27 | 2022-12-13 | 北京中佳瑞通科技有限公司 | Digital twin monitoring system |
| CN116822353A (en) * | 2023-06-21 | 2023-09-29 | 盐城工学院 | Digital twin model rapid construction method in manufacturing process |
| CN117351132A (en) * | 2023-12-04 | 2024-01-05 | 山东再起数据科技有限公司 | Remote terminal equipment rendering method based on digital contracture and tcp transmission control protocol |
| CN117391625A (en) * | 2023-10-18 | 2024-01-12 | 上海形拓科技有限公司 | Intelligent manufacturing management system and method based on digital twinning |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115469594A (en) * | 2022-09-27 | 2022-12-13 | 北京中佳瑞通科技有限公司 | Digital twin monitoring system |
| CN116822353A (en) * | 2023-06-21 | 2023-09-29 | 盐城工学院 | Digital twin model rapid construction method in manufacturing process |
| CN117391625A (en) * | 2023-10-18 | 2024-01-12 | 上海形拓科技有限公司 | Intelligent manufacturing management system and method based on digital twinning |
| CN117391625B (en) * | 2023-10-18 | 2024-04-02 | 上海形拓科技有限公司 | Intelligent manufacturing management system and method based on digital twinning |
| CN117351132A (en) * | 2023-12-04 | 2024-01-05 | 山东再起数据科技有限公司 | Remote terminal equipment rendering method based on digital contracture and tcp transmission control protocol |
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