CN115203842A - Digital twinning system of hot stamping forming production line and construction method - Google Patents
Digital twinning system of hot stamping forming production line and construction method Download PDFInfo
- Publication number
- CN115203842A CN115203842A CN202210796529.3A CN202210796529A CN115203842A CN 115203842 A CN115203842 A CN 115203842A CN 202210796529 A CN202210796529 A CN 202210796529A CN 115203842 A CN115203842 A CN 115203842A
- Authority
- CN
- China
- Prior art keywords
- module
- data
- production line
- scene
- hot stamping
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/17—Mechanical parametric or variational design
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/08—Thermal analysis or thermal optimisation
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Geometry (AREA)
- Theoretical Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Evolutionary Computation (AREA)
- Computer Hardware Design (AREA)
- General Engineering & Computer Science (AREA)
- Pure & Applied Mathematics (AREA)
- Mathematical Optimization (AREA)
- Mathematical Analysis (AREA)
- Computational Mathematics (AREA)
- Management, Administration, Business Operations System, And Electronic Commerce (AREA)
Abstract
The invention provides a digital twinning system and a construction method of a hot stamping forming production line, wherein the digital twinning system comprises an automatic hot stamping forming production line physical system positioned on a physical layer, a network communication, data processing and analysis system positioned on a middle layer and a three-dimensional production line virtual scene, live broadcast video, augmented reality and running state signboard display system positioned on a service layer, and the construction method comprises the following steps: (1) collecting data; (2) geometric modeling; (3) a human-machine interface; (4) constructing a scene; (5) a scene model; and (6) optimizing the scene. Through the digital twin system provided by the invention, a design and manager of the hot stamping forming production line can plan, verify, analyze and evaluate the production process, optimize the production line design, monitor the construction and operation conditions of the production line, check the real-time production information and production statistical data, and comprehensively analyze the operation and performance data, thereby continuously optimizing the efficiency of the hot stamping forming production line.
Description
Technical Field
The invention relates to a digital twinning technology oriented to the field of hot stamping forming machining and manufacturing, in particular to a digital twinning system of a hot stamping forming production line and a construction method.
Background
Design, construction, use and manager of the hot stamping forming production line need to plan and verify production process flow, create production line layout, select production equipment to perform flow simulation so as to optimize production line design, predict maintenance period, reduce or even prevent shutdown to improve equipment starting rate, and optimize personnel configuration and working condition setting of the manufacturing process in the production line operation process. The existing hot stamping forming production line has many defects in planning, scheduling, monitoring and managing processes and is inconvenient to operate, so that an information interaction and monitoring system which enables a production line design, production planning, scheduling, dispatching and manager to scientifically evaluate and adjust and visually know the construction and running conditions of the production line in real time is needed.
The digital twinning technology can symmetrically map the physical entity object of the hot stamping production line and the virtual object of the digital information model, and realize the real-time interaction of the state data of the physical entity object and the virtual object of the digital information model. Therefore, the digital twinning system of the hot stamping forming production line is constructed based on the digital twinning technology, the construction condition of the production line and the operation conditions of all entity machine equipment on the production line can be monitored at any time, the production information and the production statistical data are displayed in real time, the operation and performance data of the actual production process are comprehensively analyzed and evaluated, and the efficiency of the hot stamping forming production line is continuously optimized.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a digital twinning system of a hot stamping forming production line and a construction method thereof.
In order to meet the requirements, the technical scheme adopted by the invention is as follows: a digital twining system and a construction method of a hot stamping forming production line are provided, wherein the digital twining system of the hot stamping forming production line comprises three parts: (1) The physical system of the hot stamping forming production line positioned in the physical layer module is a flexible automatic system which is suitable for different process route requirements, and can produce different types of workpieces after special tools and control software are replaced. (2) And the network communication, data processing and analysis system positioned in the middle layer module realizes the data acquisition, processing, storage and analysis processes of the digital twin system. (3) The three-dimensional production line virtual scene, live video, augmented reality and running state billboard display system positioned in the service layer module can monitor the construction and running conditions of the production line in real time and display production statistical information and field states.
The method for constructing the digital twin system of the hot stamping forming production line comprises the following steps:
step 1, a data collecting module: and summarizing all data information of the solid object and the virtual object of the hot stamping forming production line and then dividing the data into non-model driving data and model driving data. The non-model-driven data are static type data and are stored and displayed in the Internet of things platform tool in a table form. The model driving data is dynamic data, the WebSocket protocol is used for sending the data to the Internet of things platform tool for storage, and the data is transmitted to the three-dimensional visualization engine in a JSON character string format for data linkage and binding. The data collected by the data collecting module are respectively provided for the geometric modeling and human-computer interface module through the step 2 and the step 3;
step 2, a geometric modeling module: and a digital model is constructed by adopting three-dimensional modeling software according to the geometric dimension of the entity object, and necessary lamplight, materials, texture rendering models and special effects are added, so that the three-dimensional model has real texture and is more vivid. In order to reduce the operating pressure of hardware, the model is simplified appropriately and exported to a lightweight format file, and the file is imported to the scene construction module in step 4;
step 3, a human-computer interface module: the system comprises the functions of man-machine interaction design, external input event response and the like, and aims to realize scene roaming in a three-dimensional virtual environment, so that a user has immersive visual experience. Exporting a file realizing the functions of the human-computer interface module into a lightweight format file in a three-dimensional modeling software environment, and importing the file into a scene construction module in step 4;
step 4, a scene construction module: the geometric modeling module and the function file of the human-computer interface module are further improved in a three-dimensional visualization engine development tool, namely the design effect of the human-computer interface module and the model file of the geometric modeling module are combined into one scene, scene management, scene roaming, user interface design, performance optimization and the like are carried out, the combined effect and the model file are exported to a lightweight format file, and the file is imported into the scene model module in step 5;
step 5, a scene model module: carrying out data binding on information provided by the Internet of things platform development tool in a JSON character string format in a three-dimensional visualization engine development tool, realizing real-time updating of the state information of a virtual scene, a state billboard, a live video and an augmented reality function module driven by real-time data of an entity object in the physical layer module, carrying out operation test on the function modules and feeding back the test result to a scene optimization module in step 6;
step 6, a scene optimization module: and feeding back the test operation result of the scene model module to the geometric modeling and human-computer interface module, respectively performing design optimization in the two modules, publishing the model file of the virtual scene module into a WebGL format in a three-dimensional visualization engine development tool after iteration, and integrating the model file into an Internet of things platform tool.
The Internet of things platform tool adopts a thingsBoard, the three-dimensional visualization engine adopts Unity 3D, the three-dimensional modeling software comprises blend, siemens NX or Unity 3D, and the lightweight file is an FBX format file.
The invention is based on a digital twinning technology, and further describes a construction process and an implementation method of a digital twinning system of a hot stamping forming production line by constructing a physical object system and a virtual object system of the hot stamping forming production line. The digital twin system of the hot stamping forming production line has the advantages that:
the invention drives the operation of a three-dimensional digital virtual production line through the real-time production process data acquired from a physical object system of a hot stamping forming production line, thereby visually showing the overall appearance of the production process, namely seeing which type of stamping part products and quantity are processed on a real production line under a virtual environment, the operation state and fault alarm record of the production line, the states of equipment such as a heating furnace, a press and the like, and instrument data such as an infrared temperature detector and the like; the design and manager of the production line can conveniently look up actual production data, such as roaming in a virtual production line, and clicking equipment by a mouse to see the work history, key data history curves and the like of the equipment.
The invention can continuously record the quality of each workpiece on the hot stamping forming production line and can quickly identify the quality problem in the production and manufacturing process; the customer of the hot press formed product can also view historical traceability information of the workpiece, in which quality data of each product is recorded, which will enable continuous monitoring of the product delivery, improving the quality of the delivered product and improving the manufacturing quality of the customer's product. The system of the invention can be used by a production line design and manager to comprehensively analyze the product quality and the production line operation performance data, so that the production process can be planned and verified, the design of a future production line can be optimized, the fault-free operation time of machines and equipment on the production line can be prolonged, the manufacturing cost of hot stamping products can be reduced, and the efficiency of the hot stamping production line can be optimized in a sustainable mode.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the application and together with the description serve to explain the application and are not intended to limit the application. In the drawings:
FIG. 1 schematically illustrates an overall architecture and workflow diagram of a hot stamp forming line digital twinning system according to one embodiment of the present application.
FIG. 2 schematically illustrates a physical system architecture and workflow diagram of an automated hot stamp forming line according to one embodiment of the present application.
Fig. 3 schematically illustrates a virtual system architecture and a build flow diagram of an automated hot stamp forming line according to one embodiment of the present application.
FIG. 4 schematically illustrates a data management and network communication system diagram of an automated hot stamp forming line, according to one embodiment of the present application.
Detailed Description
To make the objects, technical solutions and advantages of the present application more clear, the present application is further described in detail below with reference to the accompanying drawings and specific embodiments.
In an effort to provide a concise description of these embodiments, all features of an actual embodiment may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another.
In the following description, references to "one embodiment," "an embodiment," "one example," "an example," etc., indicate that the embodiment or example so described may include a particular feature, structure, characteristic, property, element, or limitation, but every embodiment or example does not necessarily include the particular feature, structure, characteristic, property, element, or limitation. Moreover, repeated use of the phrase "in accordance with an embodiment of the present application" although it may possibly refer to the same embodiment, does not necessarily refer to the same embodiment.
Certain features that are well known to those skilled in the art have been omitted from the following description for the sake of simplicity.
When introducing elements of various embodiments of the present invention, the articles "a," "an," and "the" are intended to mean that there are one or more of the elements. The terms "comprising," "including," "and" having an inclusive meaning may be used to specify the presence of stated elements.
(1) Overall framework of digital twin system of hot stamping forming production line
According to one embodiment of the present application, as shown in FIG. 1, the overall architecture 10 of the hot stamp forming line digital twinning system is a three-layer structure comprising: (1) The physical system of the automatic hot stamping forming production line is positioned at the physical layer 100; (2) A network communication, data acquisition, processing, storage and analysis system located in middle tier 200; (3) A three-dimensional production line virtual scene, live video, augmented reality, and operating status billboard presentation system at the service layer 300. The entity object data information in the physical layer 100 is mapped to the simulation object in the virtual space of the service layer 300 in real time through data processing and conversion of the intermediate layer 200. The virtual object in the service layer 300 completely corresponds to the physical object in the physical layer 100 in terms of dynamic and static information, and the two are virtual and real twins of the digital hot stamping forming production line.
The physical layer 100 is a physical object in a physical space of the digital twin system, and is composed of physical devices such as a machine 120, a sensor 125, an actuator 130, and a controller 135. In one embodiment of the present application, as shown in fig. 2, the machine 120 refers to all physical equipment in the hot press forming line 100, including a stereo warehouse 1005, a handling robot 1015, etc., a heating furnace 1100, a press 1080, a laser trimming station 1130, a laser welding station 1150, a robotic guided vehicle 1025, etc. The sensors 125 refer to sensing devices for various physical quantities in the machine 120, such as data sensors and transducers for temperature, oxygen content, dew point, current, speed, etc. parameters. The actuator 130 refers to various moving and actuating devices inside the machine 120, such as a heater, a servo motor, a cylinder, a valve, a solenoid valve, and the like. Controller 135 refers to all intelligent control devices that control the operation of machine 120, such as a Programmable Logic Controller (PLC), a Human Machine Interface (HMI) unit, and the like.
The devices in the physical layer 100 feed back real-time data information of specific physical objects and processes of the hot stamping production line to the intermediate layer 200 through the network communication link 215, such as temperatures of zones of the heating furnace, oxygen content, dew point, current, temperature, speed of the robot motor, tapping temperature of parts, transit time from the heating furnace to the press, temperature in the press, and down-going time and pressure holding time of the press.
The middle layer 200 implements the data acquisition, processing, storage and analysis processes of the digital twin system, including three functional modules of network communication links 210, 215, 225, 235, network communication system 205, data processing system 220 and data analysis system 230. The network communication links 210, 215, 225, 235 are distributed among the network communication system 205, the data processing system 220, the data analysis system 230, the physical layer 100, and the service layer 300. Real-time data information of the physical objects in the hot stamping line passes through the network communication links 210 and 215 and the network communication system 205 to the data processing system 220. The data processing system 220 classifies, converts, and stores the real-time data information into the data analysis system 230 via the network communication link 225 according to the application requirements of the service layer 300. The data analysis system 230 feeds back the data analysis result to the service layer 300 through the network communication link 235 according to the request information of the specific application service in the service layer 300.
Due to the complexity and unpredictability of the production process of the hot stamping forming workshop, the traditional monitoring mode adopting a data report, a two-dimensional graph and configuration software cannot meet the monitoring requirement under the current manufacturing mode. The workshop management personnel can not obtain accurate production process information in the first time, can not quickly respond to abnormal production conditions, adjust the production plan and guide workshop production. As shown in a service layer 300 in fig. 1, the present application provides a multi-level hot stamping production line operation process control mode based on a three-dimensional virtual scene 310 and a status signboard 305, and assisted by a live video 320 and an augmented reality 325.
The service layer 300 is a simulation object in a virtual space of the digital twin system, corresponds to an entity object in a physical space through a three-dimensional modeled model and a data information presentation tool, and is responsible for providing application-specific services to the physical layer. This layer includes the network communication link 235 as well as the status billboard 305, the virtual scene 310, the live video 320 and the augmented reality 325 for 4 functional modules.
Although the display effect of the status signboard 305 is not as direct as that of the three-dimensional model, it plays an irreplaceable role in the aspect of statistical information attributes (time, text, quantity, etc.), and can display the statistical information and detailed production resource status of each workpiece in real time. In one embodiment of the present application, the status billboard 305 displays the real-time status of the hot stamping line 100 and the historical data generated by the data processing system 220 in different forms, such as text, numbers, tables, dot diagrams, line graphs, dashboards, etc., and also has the function of summarizing the data in different periods (such as in seconds, minutes, hours, days, weeks, months). The three-dimensional virtual scene module 310 is a main monitoring mode, and realizes the visual control of the manufacturing process of the hot stamping forming production line from three layers of logistics, equipment and products. The live broadcast video module 320 realizes real-time visual monitoring on key links of the hot stamping production line through a plurality of industrial cameras arranged on site. The augmented reality module 325 comprehensively utilizes three-dimensional modeling, real-time tracking and registration, intelligent interaction, sensors and other technical means to superimpose virtual information on physical objects in the real world, thereby enhancing the internal data information display capability of the physical objects, such as the visual display of the motion state in the equipment.
According to one embodiment of the application, the three-dimensional scene visualization system hardware of the hot stamping forming production line digital twinning system is composed as follows: visual electronic signboards are installed in a company production workshop, an office, a dispatching room and a product display hall, a terminal computer with high graphic processing performance is equipped, a three-dimensional scene production line visual system is operated, and the systems are intercommunicated and interconnected through industrial Ethernet. Production management personnel can master the running state, the yield statistical information, the progress information, the key data historical curve and the like of the production line in real time in offices, dispatching rooms and exhibition halls like putting production workshop sites.
The visual electronic billboard adopts a high-resolution spliced large screen and comprises a matrix type multi-block spliced screen, a large screen controller, a multiplexer, a three-dimensional visual server, a video switch and the like, wherein the three-dimensional visual server is used for installing and deploying a digital twin system application of a hot stamping forming production line, and the large screen controller is used for receiving multi-channel video signals from the three-dimensional visual server and the video switch, processing, deploying and matrix mapping the video signals and displaying the video signals to different areas of the spliced screen.
(2) Physical layer construction method of digital twinning system of hot stamping forming production line
In one embodiment of the present application, as shown in FIG. 2, the exemplary hot stamp forming line 100 is flexible, automated to accommodate different process line requirements, and can produce different types of workpieces after replacement of specialized tools and control software. The production line is divided into three functional modules: (1) a logistics module 105 for preparing materials and transferring workpieces. (2) a pre-processing module 110 for producing a hot press formed workpiece. And (3) a post-processing module 115 for hot-press forming the workpiece.
After the system 100 has obtained the production plan order, it is responsible for preparing raw materials, transferring raw materials, semi-finished goods, and finished workpieces by the logistics module 105. The module 105 includes a stereoscopic warehouse 1005, a handling robot station 1015, and a automated guided vehicle 1025. The stereoscopic warehouse 1005 puts the prepared raw material in the loading area of the transfer robot station 1015, and transmits a raw material preparation command 1010 to the transfer robot station 1015. After automated guided vehicle 1025 arrives at the loading location, a request material command 1020 is sent to transfer robot station 1015. After receiving the instructions 1010 and 1020, the handling robot station 1015 puts the raw materials onto the automated guided vehicle 1025, and feeds back the execution result instructions 1010 and 1020 to the stereoscopic warehouse 1005 and the automated guided vehicle 1025, respectively. After the automated guided vehicle 1025 takes the raw material, it begins to enter the pre-processing module 110 for semi-finished product processing.
The pre-processing module 110 is responsible for hot stamping the raw material into a green part. The module 110 includes a loading robot station 1035, a cold charge transfer cart 1045, handling robot stations 1055, 1090, a thickness/marking station 1065, a press 1080, a heating furnace 1100, and a temperature controller 1110.
The feeding manipulator station 1035, upon receiving a material pick-up command 1030 sent by the automated guided vehicle 1025, sends a command 1040 to the cold material transfer vehicle 1045 requesting a feed. After receiving the request 1040, the cold material transfer trolley 1045 sends a feedback instruction 1040 to the feeding manipulator station 1035 to allow feeding if feeding is possible, or else waits until feeding is possible. The feeding robot station 1035, upon receiving the feedback instructions 1040 to allow feeding, feeds the material take instructions 1030 back to the automated guided vehicle 1025 and transports the material from the automated guided vehicle 1025 to the cold material transfer vehicle 1045.
After the material is present in the cold material transfer car 1045, a allow material pick command 1050 is sent to the transfer robot station 1055. The carrying manipulator station 1055 receives the instruction 1050 and then takes the material from the cold material transfer trolley 1045, sends an instruction 1060 to the thickness measuring/marking station 1065 to request thickness measuring and marking, and feeds back an execution result instruction 1050 to the cold material transfer trolley 1045.
After receiving the request 1060, the thickness/marking station 1065 sends a feedback command 1060 to the transfer robot station 1055 to allow feeding if there is an empty station, otherwise waits until there is an empty station. After receiving the feedback command 1060, the handling robot station 1055 feeds the workpiece to the thickness measuring/marking station 1065 for thickness measurement and marking.
According to a processing route established by an actual production process, if the qualified workpiece subjected to thickness measurement and marking by the working station 1065 needs to process a preformed complex part, the carrying manipulator station 1055 sends an instruction 1070 to the press 1080 for transferring. If the press 1080 feeds back instructions 1070 to allow transfer, the handling robot station 1055 transfers the work-piece to the press 1080, otherwise waits until transfer is possible. If a simple part is to be processed that does not require pre-forming, the handling robot station 1055 sends a command 1075 to the furnace 1100 requesting a transfer. The handling robot station 1055 transfers the workpiece to the heating furnace 1100 if the heating furnace 1100 feeds back a command 1075 to allow transfer, and otherwise waits until transfer is possible.
The press 1080 includes two types: preforming and final forming. If complex parts are being produced, the workpiece is first passed through a preforming press 1080, heated in a furnace 1100, and then transferred by a transfer robot station 1090 to a final forming press 1080. If a simple part is to be produced, the workpiece is transported from the transfer robot station 1055 to the heating furnace 1100 without passing through the preforming press 1080, and then transported from the transfer robot station 1090 to the final forming press 1080 after heating.
If the workpiece being produced needs to control the physical properties of its different zones, as required by the actual production process, the press 1080 sends an instruction 1105 to the thermostat 1110 requesting temperature control. After receiving the request instruction 1105, the temperature controller 1110 completes the temperature control requirement and sends an instruction 1105 to the press 1080 for feeding back the temperature control result.
According to the processing route established by the actual production process, if a complex part is produced, the preforming press 1080 finishes processing and sends an instruction 1085 to the transfer robot station 1090 requesting the transfer of the workpiece to the heating furnace 1100. Upon receiving the request command 1085, the transfer robot station 1090 transmits a command 1095 requesting feeding to the heating furnace 1100. After the heating furnace 1100 receives the request command 1095, it feeds back a feed permission command 1095 to the transfer robot station 1090 if it can feed, and otherwise waits until it can feed. Upon receipt of the command 1095 to allow feeding, the handling robot station 1090 sends a feedback command 1085 to the preform press 1080 to allow transfer and transfers the workpiece from the preform press 1080 to the oven 1100.
According to the machining route established by the actual production process, if a simple part is produced, the heating furnace 1100 completes heating of the workpiece, and then sends an instruction 1095 to the transfer robot station 1090 requesting transfer of the workpiece to the final forming press 1080. Upon receiving the request command 1095, the transfer robot station 1090 transmits a command 1085 requesting transfer to the final forming press 1080. Upon receipt of the requested transfer command 1085, the finishing press 1080 sends a feedback command 1085 to the transfer robot station 1090 to allow transfer if available, and otherwise waits until available. Upon receiving the command 1085 to permit transfer, the handling robot station 1090 transmits a feedback command 1095 to the heating furnace 1100 to permit transfer, and transports the workpiece from the heating furnace 1100 to the final forming press 1080. The finished workpiece processed by the finishing press 1080 is a semi-finished product and then enters the post-processing module 115 to complete the processing of the finished workpiece.
The post-processing module 115 is responsible for processing the semi-finished pieces to finished pieces. The module 115 includes a handling robot station 1120, a laser trimming station 1130, a transfer robot station 1140, a laser welding station 1150, and a blanking robot station 1160.
After finishing press 1080 completes the processing of the work pieces, it sends an instruction 1115 to transfer robot station 1090 requesting the transfer of the semi-finished work pieces to robot station 1120. Upon receipt of the request 1115, the carrier robot station 1120 sends an instruction 1125 to the laser trim station 1130 requesting transfer of the workpiece. Upon receipt of the request 1125, the laser trim station 1130 sends a feedback 1125 to the transfer robot station 1120 to allow transfer if the workpiece can be transferred, or else waits until transfer is possible. Upon receipt of feedback command 1125 to allow transfer, the transfer robot station 1120 sends feedback command 1115 to the transfer robot station 1090 to allow transfer, and transfers the workpiece from the transfer robot station 1090 to the laser trim station 1130.
After the laser trim station 1130 completes processing the workpiece, an instruction 1135 is sent to the transfer robot station 1140 requesting transfer of the workpiece to the laser welding station 1150. Upon receiving the request 1135, the transfer robot station 1140 sends a request 1145 to the laser welding station 1150 to transfer the workpiece. After the laser welding station 1150 receives the request command 1145, it sends a feedback command 1145 to the transfer robot station 1140 to allow transfer if possible, or else waits until transfer is possible. After receiving the feedback command 1145 to allow transfer, the transfer robot station 1140 sends a feedback command 1135 to the laser trim station 1130 to allow transfer, and transfers the workpiece from the laser trim station 1130 to the laser welding station 1150.
After the laser welding station 1150 has completed processing the workpiece, it sends instructions 1155 to the blanking robot station 1160 requesting that the finished workpiece be transferred to the automated guided vehicle 1025. The blanking robot station 1160, upon receiving the request command 1155, sends a command 1165 to the automated guided vehicle 1025 requesting transfer of the workpiece. Upon receipt of the request 1165, automated guided vehicles 1025 send feedback 1165 to the robot drop station 1160 to allow transfer if transfer is possible, or wait until transfer is possible. After receiving the feedback command 1165 to allow transfer, the blanking robot station 1160 sends a feedback command 1155 to the laser welding station 1150 to allow transfer, and transfers the workpiece from the laser welding station 1150 to the automated guided vehicle 1025. In the logistics module 105, the automated guided vehicle 1025 transfers the finished work piece into the stereoscopic warehouse 1005.
Automated guided vehicle 1025, after obtaining the finished workpiece, sends an instruction 1020 to transfer robot station 1015 requesting that the finished workpiece be transferred to stereoscopic warehouse 1005. Upon receiving the request command 1020, the transfer robot station 1015 transmits a command 1010 to the stereoscopic warehouse 1005 to request the transfer of the workpiece. After receiving the request command 1010, the stereoscopic warehouse 1005 sends a feedback command 1005 to the transfer robot station 1015 to allow the transfer if the transfer is available, otherwise, the stereoscopic warehouse 1005 waits until the transfer is available. After receiving feedback instructions 1005 to allow transfer, transfer robot station 1015 sends feedback instructions 1020 to automated guided vehicle 1025 to allow transfer, and transfers the workpiece from automated guided vehicle 1025 to stereoscopic warehouse 1005.
(3) Intermediate layer construction method of digital twin system of hot stamping forming production line
The real-time operating status information of the physical objects, such as the various sensors 125, actuators 130, controllers 135, and machines 120, in the physical layer 100 of the hot stamping line is communicated to the intermediate layer 200 via the network communication link 215 for data format conversion, storage, and analysis. As shown in fig. 4, the network communication system 205 is an important link for implementing data information interconnection of the hot stamping production line, and includes two functional modules, namely bus data 205A and discrete data 205B. The two communication modules are responsible for transferring real-time data of the physical layer 100 into the data processing system 220. Data processing system 220 includes four functional modules: data collection software 220A, data collection tool 220B, data concentrator 220C, and data processing server 220D. Some data may be passed through the data processing system 220 and then directly transmitted to a particular application of the service layer 300 by the ethernet communication link 315; still other data may need to be transmitted to the data analysis system 230 for further analysis. The data analysis system 230 includes three functional modules, namely, a real-time database 230A, a historical database 230B, and a data analysis server 230C, and completes data analysis, mining, and preparation according to specific application requirements of the service layer 300, and provides the data to the service layer 300 through an interface unified with the data processing system 220.
Because of a large number of automation manufacturers and a large number of standards for communication protocols between automation systems, it is necessary to integrate software and hardware data communications of different manufacturers in a flexible manner. OPC UA is a standardized technical framework that integrates information model definitions, services and communication standards. The OPC UA server can be connected to field devices such as programmable controllers, smart meters, etc. of most automation vendors via ethernet, so in one embodiment of the present application, the bus data 205A module uses the OPC UA protocol to obtain data from the OPC UA server of the physical layer 100 and transmit the information to the data collection software 220A module via the network communication links 210, 215. The data collection software 220A module employs an OPC UA client to transmit data information obtained from the bus data 205A module to the data processing server 220D module via the network communication link 210.
Some entity objects in the physical layer 100 do not support the OPC UA protocol but support other field bus communication protocols, such as the Profinet protocol in one embodiment of the present application. The bus data 205A module thus transmits the corresponding data information from the Profinet master site side of the physical layer 100 via the network communication links 210, 215 into the data acquisition tool 220B module. The data acquisition tool 220B module uses the Profinet protocol to transfer the data information obtained from the bus data 205A module from the station side via the network communication link 210 into the data processing server 220D module.
There are also some physical objects in the physical layer 100 that do not support the communication method of the industrial fieldbus, such as the 0-10V status signal of some meters, the 4-20 mA output signal of the thermostat, or some switching value signal, etc., so that these data signals need to be transmitted from the physical objects in the physical layer 100 to the data concentrator 220C module via the network communication links 210, 215 in the discrete data module 205B. The data concentrator 220C module transmits the acquired discrete data to the data processing server 220D module via the network communication link 210.
Twin data representing the real and complete running state of the entity production line in the physical layer 100 is heterogeneous and multi-source data flow, and needs to be classified, summarized, uniformly characterized and the like in a data processing server 220D module, and then result data is transmitted to a data processing system 230 through an ethernet link 225, and the data is further analyzed so as to provide data support service for upper-layer application.
According to the specific application requirements of the service layer 300, some data passes through the data processing server 220D module and is then directly transmitted to the specific application of the service layer 300 by the ethernet communication link 315; still other data needs to be transmitted to the real-time database 230A and the historical database 230B by the ethernet communication link 225, then transmitted to the data analysis server 230C by the ethernet communication link 225, further analyzed, mined and prepared according to the specific application requirements of the service layer 300, and provided to the service layer 300 by the ethernet communication link 315 through an interface unified with the data processing system 220.
In an embodiment of the application, the middle layer realizes equipment connection, data acquisition, data storage, data analysis, application service development and Web front-end system integration based on the strong ubiquitous network connection, flexible data management and rapid application development capability of an Internet of things platform tool thingsBoard.
In one embodiment of the present application, the network communication system 205 employs network switches, wired and wireless routers, and the like; the data processing system 220 employs personal computers PC, raspberry Pi and Arduino, etc. small edge computing devices; the data analysis system 230 is a commercial workstation computer, and realizes the partition selection, storage, cataloguing and indexing of production line data based on a data management engine consisting of CentOS7.0, postgreSQL and a timescaleDB time sequence database; and finally, realizing information interaction between the service layer application and the industrial Internet of things platform based on a Get interface mode of the Restful architecture.
(4) Service layer construction method of digital twin system of hot stamping forming production line
By constructing a digital twin system of a hot stamping forming production line and a three-dimensional scene data processing technology research, design simulation, analysis and optimization are carried out on all links of the production line, such as equipment beat, production plan and scheduling and production process flow, multi-objective optimization design of support flow scheduling, equipment configuration, process flow and production planning is supported, and the flexibility and the intelligentization capability of the production line are improved. Meanwhile, the production line key equipment and regions are monitored in real-time video, and the augmented reality technology is combined for application, so that the dynamic information of the production process, the internal condition of the equipment and the historical action process are displayed in real time, and the abnormal conditions of the production field, such as abnormal temperature zone distribution, transportation overtime, pressure maintaining overtime, over-standard temperature, sudden stop of the equipment and other production emergency conditions, are responded in time.
The hot stamping production line digital twinning system ultimately presents the user with what is presented by the service layer module 300. The building of the service layer module 300 is a system engineering of multi-software collaborative development and multi-function module mutual collaboration. In an embodiment of the application, a ThingsBoard internet of things platform is used as a data application bus, and the development service layer module 300 is designed by using blend, siemens NX and Unity 3D multi-software collaborative modeling. As shown in fig. 3, the construction process of the service layer module 300 mainly includes 6 functional modules, i.e., data collection 3105, geometric modeling 3120, scene optimization 3140, human-machine interface 3145, scene construction 3160, and scene model 3170.
In order to construct a three-dimensional virtual scene, first, all data information of the physical object of the physical layer 100 and the virtual object of the service layer 300 is summarized in the collected data 3105 module, where the data has static types, such as the attributes of the geometric size of the machine 120, the raw material attributes, the workpiece indexes, the communication address of the sensor 125 and the type, quantity, and frequency of the transmitted data, the communication addresses and the communication protocols of the actuator 130 and the controller 135, the types, the data types and the quantity of the charts displayed by the status signboard 305 and the augmented reality 325, the communication addresses and the communication protocols of the industrial cameras in the live video 320, and the like; and dynamic types such as automatic, manual, stop-running status information of the machine 120, alarm information, production volume, tempo data, status data of the sensors 125 during operation of the apparatus, feedback results of the actuators 130, command contents of the controller 135, and the like.
The collect data 3105 module is to separate all data into non-model driven data and model driven data. The non-model driven data is static type data, stored and presented in ThingsBoard in tabular form. The model driving data is dynamic data, and the data is sent to a ThingsBoard internet of things platform for storage by using a WebSocket protocol in the data processing system 220, and is transmitted to a Unity 3D engine in a JSON character string format for data linkage and binding. The aggregated data from collected data 3105 is passed through steps 3115 and 3110 to provide information to geometry 3120 and human interface 3145 modules, respectively.
The geometric modeling 3120 module is a basis for virtual scene construction, a digital model is constructed by using three-dimensional modeling software blend according to the geometric dimensions of the entity objects in the machine 120, and necessary light, material, texture rendering models and special effects are added, so that the three-dimensional model has real texture and is more vivid. In order to reduce the operating pressure of the hardware, the model is appropriately simplified and exported as an FBX format file. The model file is imported into the scene construction 3160 module in step 3125.
The human-computer interface 3145 module includes functions of human-computer interaction design, external input event response and the like, and aims to realize scene roaming in a three-dimensional virtual environment, so that a user has an immersive visual experience. Files that implement the functionality of the human machine interface 3145 are exported in the blend software environment into the FBX format, which is imported into the scene building 3160 module in step 3155.
The scene construction 3160 module is used for further improving the functions of the geometric figure 3120 and the human-computer interface 3145 module in Unity 3D, that is, the design effect of the human-computer interface 3145 and the model file of the geometric figure 3120 are combined into one scene, and scene management, scene roaming, UI interface design, performance optimization and the like are performed. The resulting file output by the scene construction 3160 module is then imported into the scene model 3170 module in step 3165.
The scene model 3170 module is used for performing data binding on information provided by a ThingsBoard internet of things platform in a JSON string format in Unity 3D, so as to realize real-time update of the real-time data-driven virtual scene model, the state signboard 305, the live video 320 and the augmented reality 325 module state information based on the physical layer 100 entity object. In order to balance the contradiction between the complexity of virtual scene rendering and real-time rendering and ensure the fluency of the system in large-scale scenes, the virtual scene needs to be run and optimized, so the scene model 3170 module feeds back the result of the test running to the scene optimization 3135 module in step 3140.
The scene optimization 3135 module feeds back the results of the test run of the scene model 3170 module to the geometry 3120 and the human-machine interface 3145 modules in steps 3130 and 3150, performs design optimization in these two modules, and after iteration, publishes the virtual scene model 3170 model file in Unity 3D to WebGL format and integrates into ThingsBoard platform.
The above-mentioned embodiments only show some embodiments of the present invention, and the description thereof is more specific and detailed, but should not be construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present invention should be subject to the claims.
Claims (7)
1. A digital twinning system and method of construction for a hot stamp forming line, the system comprising:
the physical layer module is an entity object in a physical space of the digital twin system, is used for constructing an automatic hot stamping forming production line which is flexible and meets the requirements of different process routes, and can produce different types of workpieces after replacing special tools and control software;
the middle layer module is used for constructing a network system for communicating the physical layer module and the service layer module, realizing the data acquisition, processing and storage processes of the digital twin system and quickly establishing a real-time database and an expert knowledge base for the operation of the hot stamping production line;
and the service layer module is a simulation object in the virtual space of the digital twin system, corresponds to the entity object in the physical space through the three-dimensional modeled model and the data information display tool, and is responsible for providing the service specific to the application program for the physical layer.
The system is based on the actual business process of the production line and faces to the hot stamping forming production process, and the construction method of the system comprises 6 functional modules including data collection, geometric modeling, scene optimization, a human-computer interface, scene construction and a scene model, and 6 steps among the modules.
2. The hot stamp forming line digital twinning system and method of construction of claim 1, wherein: the physical objects of the physical layer module of the hot stamping forming production line comprise machine equipment and sensors, actuators and controllers attached to the machine equipment.
3. The hot stamp forming line digital twinning system and method of construction as claimed in claim 1, wherein: the physical layer module of the hot stamping forming production line comprises a material preparation module, a material transfer module, a pretreatment module and a post-treatment module, wherein the material preparation module is used for preparing materials and transferring workpieces, the pretreatment module is used for producing hot stamping forming workpieces, and the post-treatment module is used for hot stamping forming workpieces.
4. The hot stamp forming line digital twinning system and method of construction of claim 1, wherein: the logistics module of the hot stamping forming production line comprises a stereoscopic warehouse, a carrying manipulator station and an automatic guided vehicle, the pretreatment module comprises a feeding manipulator station, a cold material transfer vehicle, a carrying manipulator station, a thickness measuring/marking station, a press, a heating furnace and a temperature controller, and the post-treatment module comprises a carrying manipulator station, a laser trimming station, a transfer manipulator station, a laser welding station and a discharging manipulator station.
5. The hot stamp forming line digital twinning system and method of construction as claimed in claim 1, wherein: the middle layer module of the hot stamping forming production line comprises a network communication link, a network communication system, a data processing system and a data analysis system.
6. The hot stamp forming line digital twinning system and method of construction of claim 1, wherein: the three-dimensional hot stamping production line service layer module monitors key equipment and areas of a production line in real-time video and combines with augmented reality technology application, thereby showing dynamic information of a production process, internal conditions of the equipment and historical action processes in real time and responding to abnormal conditions of a production site in time.
7. The hot stamp forming line digital twinning system and method of construction as claimed in claim 1, wherein said method of construction includes:
step 1, the data collecting module collects all data information of the solid object and the virtual object of the hot stamping forming production line and then divides the data information into non-model driving data and model driving data. The non-model-driven data is static type data and is stored and displayed in the Internet of things platform tool in a table form. The model driving data is dynamic data, the WebSocket protocol is used for sending the data to the Internet of things platform tool for storage, and the data is transmitted to the three-dimensional visualization engine in a JSON character string format for data linkage and binding. The data collected by the data collecting module are respectively provided to the geometric modeling and human-computer interface module through the step 2 and the step 3;
and 2, the geometric modeling module constructs a digital model by adopting three-dimensional modeling software according to the geometric size of the entity object, and adds necessary light, materials, texture rendering models and special effects to ensure that the three-dimensional model has real texture and is more vivid. In order to reduce the operating pressure of hardware, the model is simplified appropriately and exported to a lightweight format file, and the file is imported to the scene construction module in step 4;
and 3, the human-computer interface module comprises functions of human-computer interaction design, external input event response and the like, and aims to realize scene roaming in a three-dimensional virtual environment and enable a user to have immersive visual experience. Exporting a file realizing the functions of the human-computer interface module into a lightweight format file in a three-dimensional modeling software environment, and importing the file into a scene construction module in step 4;
step 4, the scene construction module further improves the geometric modeling module and the function file of the human-computer interface module in the three-dimensional visualization engine development tool, namely, the design effect of the human-computer interface module and the model file of the geometric modeling module are combined into one scene, scene management, scene roaming, UI interface design, performance optimization and the like are carried out, and the file is led into the scene model module in step 5;
step 5, the scene model module performs data binding on information provided by the Internet of things platform development tool in a JSON character string format in a three-dimensional visualization engine development tool, realizes real-time updating of the state information of the virtual scene, the state signboard, the live video and the augmented reality module driven by real-time data of the entity object in the physical layer module, performs operation test on the modules and feeds back the test result to the scene optimization module in step 6;
and 6, feeding back the test operation result of the scene model module in the step 5 to the geometric modeling and human-computer interface module by the scene optimization module, respectively performing design optimization in the two modules, issuing the model file of the virtual scene module into a WebGL format in a three-dimensional visualization engine development tool after iteration, and integrating the model file into an Internet of things platform tool.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210796529.3A CN115203842A (en) | 2022-07-06 | 2022-07-06 | Digital twinning system of hot stamping forming production line and construction method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210796529.3A CN115203842A (en) | 2022-07-06 | 2022-07-06 | Digital twinning system of hot stamping forming production line and construction method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115203842A true CN115203842A (en) | 2022-10-18 |
Family
ID=83580204
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210796529.3A Pending CN115203842A (en) | 2022-07-06 | 2022-07-06 | Digital twinning system of hot stamping forming production line and construction method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN115203842A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115374574A (en) * | 2022-10-25 | 2022-11-22 | 天津天锻航空科技有限公司 | Digital twin system for impact hydroforming and construction method |
| CN116244953A (en) * | 2023-03-13 | 2023-06-09 | 吉林化工学院 | Heating furnace energy saving monitoring and predicting system and method based on digital twin body |
| CN116366466A (en) * | 2023-05-23 | 2023-06-30 | 烽台科技（北京）有限公司 | Method, apparatus and readable storage medium for restoring industrial field environment |
| CN117171920A (en) * | 2023-11-02 | 2023-12-05 | 恩葛智能科技(南通)有限公司 | Aluminum foil cutlery box stamping forming control method and system |
| CN117311196A (en) * | 2023-08-28 | 2023-12-29 | 河北界斯智能装备制造有限公司 | Linkage control system and method for hot stamping intelligent control integrated cabinet |
-
2022
- 2022-07-06 CN CN202210796529.3A patent/CN115203842A/en active Pending
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115374574A (en) * | 2022-10-25 | 2022-11-22 | 天津天锻航空科技有限公司 | Digital twin system for impact hydroforming and construction method |
| CN115374574B (en) * | 2022-10-25 | 2023-03-24 | 天津天锻航空科技有限公司 | Digital twinning system for impact hydroforming and construction method |
| CN116244953A (en) * | 2023-03-13 | 2023-06-09 | 吉林化工学院 | Heating furnace energy saving monitoring and predicting system and method based on digital twin body |
| CN116366466A (en) * | 2023-05-23 | 2023-06-30 | 烽台科技（北京）有限公司 | Method, apparatus and readable storage medium for restoring industrial field environment |
| CN116366466B (en) * | 2023-05-23 | 2023-08-22 | 烽台科技（北京）有限公司 | Method, apparatus and readable storage medium for restoring industrial field environment |
| CN117311196A (en) * | 2023-08-28 | 2023-12-29 | 河北界斯智能装备制造有限公司 | Linkage control system and method for hot stamping intelligent control integrated cabinet |
| CN117171920A (en) * | 2023-11-02 | 2023-12-05 | 恩葛智能科技(南通)有限公司 | Aluminum foil cutlery box stamping forming control method and system |
| CN117171920B (en) * | 2023-11-02 | 2024-03-08 | 恩葛智能科技(南通)有限公司 | Aluminum foil cutlery box stamping forming control method and system |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN115203842A (en) | Digital twinning system of hot stamping forming production line and construction method | |
| CN111857065B (en) | Intelligent production system and method based on edge calculation and digital twinning | |
| Fan et al. | A digital-twin visualized architecture for Flexible Manufacturing System | |
| JP7037204B2 (en) | Smart factory monitoring methods and systems | |
| Liu et al. | A systematic development method for cyber-physical machine tools | |
| Ma et al. | A digital twin-driven production management system for production workshop | |
| CN107861478B (en) | A kind of parallel control method in intelligence workshop and system | |
| Lin et al. | Concept design of a system architecture for a manufacturing cyber-physical digital twin system | |
| EP4310764A1 (en) | Aviation industry cluster-oriented manufacturing process management and control system architecture | |
| CN106022523B (en) | A kind of automatic production line Optimization Design based on integrated emulation | |
| CN112270508A (en) | Digital twin smart cloud scheduling method meeting personalized customized production | |
| Cheng et al. | A digital twin-driven approach for on-line controlling quality of marine diesel engine critical parts | |
| CN106094777A (en) | A kind of industry internet Hub device | |
| CN113093680A (en) | FIMS system architecture design method based on digital twin technology | |
| CN105843203A (en) | Intelligent production line process monitoring system | |
| CN106897817A (en) | A kind of construction speed Visualized management system and method based on augmented reality | |
| CN109298685A (en) | Digital factory implementation method, digital factory realize system and digital factory | |
| CN106774192A (en) | Heat treatment intelligence system and its control method based on MES | |
| CN106647336A (en) | Simulation-based intelligent monitoring system for aircraft assembling process | |
| CN108681878A (en) | The acquisition of intelligent plant production line data and billboard management system and method | |
| Ćwikła et al. | Problems of integration of a manufacturing system with the business area of a company on the example of the Integrated Manufacturing Systems Laboratory | |
| CN106774211A (en) | A kind of 4.0 experience systems of linear pattern industry | |
| CN108829048A (en) | A kind of information analysis system and method based on liquid crystal glass base production and processing | |
| CN115129004A (en) | Intelligent production system and method based on edge calculation and digital twinning | |
| Yan et al. | Digital twin-driven rapid customized design of board-type furniture production line |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |