CN116756042A - Data integrated management system and method based on digital twin technology - Google Patents
Data integrated management system and method based on digital twin technology Download PDFInfo
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Abstract
The invention discloses a data integrated management system and method based on a digital twin technology, and belongs to the technical field of data management. The system comprises a product design digitizing module, a product manufacturing equipment modeling module, a product difference judging module and a manufacturing adjusting module; the output end of the product design digitizing module is electrically connected with the input end of the product manufacturing equipment modeling module, the output end of the product manufacturing equipment modeling module is electrically connected with the input end of the product difference judging module, and the output end of the product difference judging module is electrically connected with the input end of the manufacturing adjusting module; the invention also provides a method for implementing the system, the invention establishes a digital twin model of actual production equipment on the production line, the production equipment data on different production lines are subjected to integrated management of the data by a digital twin technology, the equipment parameters on the production line are modified in real time according to the digital twin model, the probability of producing unqualified products on the production line is reduced, and the production efficiency of factories is improved.
Description
Technical Field
The invention relates to the technical field of data management, in particular to a data integrated management system and method based on a digital twin technology.
Background
The digital twin technology aims at entity equipment in the real world, utilizes physical modeling, sensor updating and operation history data to establish a completely consistent corresponding model in the digital world, and dynamically simulates, monitors, analyzes and controls the entity equipment in a digital mode.
In actual production of products, equipment data standards among different production lines are disordered, data island among the production lines is serious, data cannot be managed and effectively applied, and a system for integrally managing data at each production stage and playing a role in data integration analysis is lacking.
When a product designed by a designer is produced in an actual production line for the first time, specific equipment parameters are required to be debugged to manufacture the product meeting the requirements, and for different production lines, how to automatically adjust the equipment parameters while acquiring test data becomes a problem to be solved.
Disclosure of Invention
The invention aims to provide a data integrated management system and method based on a digital twin technology, so as to solve the problems in the background technology.
In order to solve the technical problems, the invention provides the following technical scheme: the system comprises a product design digitizing module, a production and manufacturing equipment modeling module, a product difference judging module and a manufacturing adjusting module;
the product design digital module is used for designing an analog manufacturing process of processing raw materials into products, establishing models of the raw materials and digital processing equipment, designing a processing flow, imaging a designed idea, selecting the processing raw materials, selecting the processing equipment, dividing the designed product model into a plurality of parts, and corresponding to the processing flow; the product manufacturing equipment modeling module is used for collecting data of manufacturing equipment for manufacturing products, transmitting the equipment data in real time, constructing a digital twin model and adjusting the parameters of the manufacturing equipment according to the model; the product difference judging module is used for comparing the difference of products in the production process of different production lines, carrying out early warning on the production lines of which the products do not meet the requirements, wherein the equipment parameters of the different production lines are different, the semi-finished products produced in each production stage are different, and the difference is gradually amplified along with the complicating of the product processing flow, so that the products cannot meet the design requirements; the manufacturing adjustment module is used for tracing the processing reasons of the semi-finished products at the stage of overlarge difference, judging the specific scheme of adjusting production equipment, and judging whether to adjust the production environment, raw materials or design scheme;
the output end of the product design digitizing module is electrically connected with the input end of the product manufacturing equipment modeling module, the output end of the product manufacturing equipment modeling module is electrically connected with the input end of the product difference judging module, and the output end of the product difference judging module is electrically connected with the input end of the manufacturing adjusting module.
The product design digital module comprises a raw material model building unit, a digital processing equipment model building unit and a processing flow design unit;
the raw material model building module is used for determining raw materials required by designing a product, acquiring data of the required raw materials and building a model, and carrying out three-dimensional modeling on the geometric structure and the appearance of a physical entity of the raw materials;
the digital processing equipment model building unit is used for obtaining original setting data of the product processing equipment and building a standard digital model of the processing equipment, and not only comprises the steps of carrying out three-dimensional modeling on the geometric structure and the appearance of a physical entity, but also carrying out full-digital modeling and simulation on information such as the operation mechanism, an internal and external interface, software, a control algorithm and the like of the physical entity, wherein the original setting data is equipment standard data, is not actual data on actual production equipment, but is equipment factory-leaving data;
the processing flow design unit is used for determining the processing flow of product manufacture according to the designed product, the needed raw materials and the processing equipment.
The product manufacturing equipment modeling module comprises a processing equipment data acquisition unit, a processing equipment data transmission unit and a processing equipment modeling simulation unit;
the processing equipment data acquisition unit is used for acquiring real-time data and historical operation data of processing equipment on a production line, the actual acquired data is different from the directly acquired data, and various sensors are used for acquiring actual production data on the original data;
the processing equipment data transmission unit is used for transmitting processing equipment data and data between the digital twin model in real time, the processing equipment data transmission unit not only transmits the data on the actual processing equipment to the digital twin model to perfect the digital twin model, but also transmits parameters of the modification equipment on the digital twin model to a controller of the actual processing equipment, various parameters of a physical entity can be truly represented in the digital twin model, the change of the digital twin model can truly reflect the change of the physical entity, and the digital twin model can also control the equipment to carry out appointed adjustment;
the processing equipment modeling simulation unit is used for establishing a digital twin model of the actual production equipment according to the original setting data, the real-time transmitted data of the actual processing equipment and the historical operation data.
The product difference judging module comprises a qualified product parameter threshold input unit, a difference judging unit and a data storage unit;
the qualified product parameter threshold value input unit is used for inputting a parameter threshold value of a qualified product; the difference judging unit is used for judging whether the products of all the production lines are qualified or not, and marking and early warning the production lines of which the products do not meet the requirements; the data storage unit is used for data of the processing process of each digital twin model production line, and the stored data comprise processed semi-finished product data from raw materials of different production lines in the production process to each stage of digital products.
The manufacturing adjustment module comprises a difference cause tracing unit, an adjustment direction selection unit and an adjustment improvement unit;
the difference cause tracing unit is used for tracing the causes of the product which do not meet the requirements, including the causes of the production line, the production environment, the raw material and the design proposal; the adjusting direction selecting unit is used for selecting the adjusting direction of the production line of which the product is not in accordance with the requirement; the adjustment improvement unit is used for determining a specific scheme of adjustment.
A data integrated management method based on digital twin technology comprises the following steps:
s1, collecting data of raw materials and original setting data of processing equipment by a system, establishing a digital model of the raw materials and a theoretical digital model of the processing equipment, and determining a product processing flow;
s2, transmitting data to a system in real time by using a sensor on an actual production line, and establishing an actual digital twin model by combining theoretical digital model data, real-time transmitted operation data and historical operation data by using the system, wherein entity equipment on the actual production line is provided with the sensor and a controller;
s3, the actual digital twin model and the theoretical digital model are used for producing digital products by using the digital model of the raw materials, the processing steps in the manufacturing process of the raw materials and the products, the semi-finished products at each stage in the manufacturing process of the products of different production lines and the digital products of different production lines are marked, and the data are stored to generate a digital twin total model of the production line;
s4, inputting a data threshold value calibrated as a qualified product by a designer, screening out a disqualified product by a system, and tracing the processing steps of the disqualified product;
s5, analyzing reasons for unqualified products, and determining the improvement direction and the specific scheme.
In step S1, the system acquires geometric structure data and material parameter data of raw materials, a digital model of the raw materials is built, the selection of the raw materials needs to consider the processing precision and consistency, the difference of the raw materials of different batches on geometric dimensions and material parameters is tiny, the system acquires the originally set theoretical data of production equipment, a theoretical digital model of the processing equipment is built, the system acquires physical design data of products, the physical design data are digitized and then split into processing steps, the flow of processing products by the theoretical digital model is determined, the theoretical digital model processes the products, the design ideas of the products are imaged, the flow corresponds to the flow of a production line in actual processing, the difference between new products of the same class and the processing flow of the existing products is small, and the existing production line is simply modified;
the step S2 comprises the following specific steps:
s201, transmitting historical operation data and real-time state data to a system by an entity device sensor on a physical production line;
s202, a system obtains a theoretical digital model of processing equipment and historical running state data of entity equipment on a physical production line, and an actual digital twin model is constructed;
s203, the digital twin model corresponds to the sensor and the controller on the physical equipment on the physical production line, data acquired by the sensor on the physical equipment are transmitted to the digital twin model in real time, and the controller on the physical equipment modifies the parameters of the physical equipment while the parameters of the equipment in the digital twin model are modified.
The step S3 comprises the following specific steps:
s301, manufacturing digital products by a digital model and a digital twin model of each actual production line;
s302, storing and marking raw material data, processing step data in all digital product manufacturing processes, semi-finished product data at each stage in the product manufacturing process of different production lines and digital product data of different production lines;
s303, integrating the digital model and the digital twin model of each actual production line to generate a production line digital twin total model, taking the production process of producing digital products by the digital model as a main axis, taking the production process of producing digital products by the digital twin model of the other actual production lines as a branch line, and forming a new branch line by the difference of semi-finished product data in each production stage on the production line digital twin total model;
dividing the production flow of the product into a plurality of stages according to the number of processing equipment, marking the product as one stage after each processing of one equipment from raw materials to finished products, and recording the data of the semi-finished products produced in the stage; recording all production processes of producing digital products by using a digital model, taking the production processes as a reference axis, sequentially recording production process data of producing the digital products by using a digital twin model of an actual production line, and judging the difference between semi-finished products of each stage of the digital twin model of the actual production line and semi-finished product data of each stage of a main axis from the processing of raw materials; if the difference value exceeds the difference range set by design manager, a branch line is separated from the node of the production stage, the data of the subsequent processing stage of the production line is recorded on the branch line, and the semi-finished product data and the difference value branch line are in direct proportion to the angle of the main axis; if the difference value does not exceed the difference range set by design manager, recording the semi-finished product data of the production stage of the production line and the semi-finished product data of the main axis together, and judging the data of the subsequent production stage until the production flow is finished; if the semi-finished product data of the next actual production line at the production stage and the data of one of the existing lines do not exceed the difference range set by design manager, recording the data of the two lines at the production stage together; and inputting all production process data of the digital twin model of the actual production line into a system.
The design of the processing flow of a new product is based on theoretical standard parameters of a production line, but equipment parameters on an actual production line are adjusted by the actual conditions of the previous production products, so that equipment and theoretical equipment of different actual production lines are different, equipment parameters in a digital model modeled by theoretical parameter standards are optimal data considering the production products at the beginning of the design, so that the digital twin model of other actual production lines are branch lines by taking the design as a main axis, the branch lines are compared with the main axis, the difference between the equipment parameters on the actual production line and the designed parameters can be seen at which production stages, the production equipment and the production flow corresponding to each data parameter of the product are respectively, and the adjusted reference direction can be obtained according to the main axis as a standard.
The digital twin total model integrates the production equipment data of all actual production lines, so that technicians can find out some outlier branch lines in time, problems can be found and adjusted, meanwhile, the data on the production lines are integrated, and the utilization rate of the data is increased.
In the steps S4-S5, the designer inputs the parameter threshold value of the qualified product, and judges whether the reason for producing the unqualified product is related to production equipment or not;
performing cluster analysis on the production environments of the qualified products and the unqualified products, and judging that the reason for producing the unqualified products is related to the production environment if the qualified products and the unqualified products are divided into two clusters;
if all the products cannot be qualified or the qualified products have irreproducibility, judging that the reason for producing the unqualified products is related to the raw materials or the design scheme, wherein the qualified products have the irreproducibility, namely that under the identical conditions, the processed products have qualified products and unqualified products, and no regularity exists;
if the qualified products can be processed by adjusting the equipment parameters of the production line of the unqualified products, and the reasons for producing the unqualified products are irrelevant to the production environment, the raw materials or the design scheme, judging that the reasons for producing the unqualified products are relevant to the production equipment;
if the reasons for producing the unqualified products are related to the production environment, raw materials or design schemes, modifying factors which lead to the unqualified products;
if the reason for producing the unqualified products is related to production equipment, selecting in an improvement direction 1 and an improvement direction 2 according to the total number of the production lines, wherein the improvement direction 1 refers to specific parameter adjustment of the production lines with the unqualified products under the condition that the total number of the production lines is small, so that the workload of a system is saved, the adjustment time of the production lines is reduced, the production efficiency is improved, and meanwhile, the method is also suitable for the products with strict parameter requirements;
in the improvement direction 1, the system screens and marks all unqualified digital products, and for each unqualified digital product, according to a digital twin total model of a production line, the system traces back to a semi-finished product at the last stage from the digital product, and checks whether product parameters of other branch lines are within the parameter threshold of the qualified product at the production stage behind the semi-finished product;
if there is a branch line with the product parameter within the parameter threshold of the qualified product, modifying the production equipment parameter of the unqualified digital product at the production stage after the semi-finished product into the production equipment parameter of the branch line with the product parameter within the parameter threshold of the qualified product;
if no branch line with the product parameters within the parameter threshold value of the qualified product exists, tracing the semi-finished product to the semi-finished product in the last stage, checking whether the product parameters of other branch lines exist in the production stage behind the semi-finished product within the parameter threshold value of the qualified product or not until the product parameters of other branch lines exist in the production stage behind the traced semi-finished product within the parameter threshold value of the qualified product;
in the improvement direction 2, the system screens and marks partial unqualified digital products, for the unqualified digital products, according to a production line digital twin total model, tracing the digital products to a semi-finished product of the previous stage, referring to main axis production equipment parameters to modify production equipment parameters of the production stage after the semi-finished product, manufacturing new digital products by the modified branch lines, judging whether the new digital product parameters of the marked branch lines are within the parameter threshold of the qualified products, wherein the premise of the improvement direction 2 is that the production lines are more, the workload of adjusting each production line one by one is larger, and the qualification range of the parameters of the products is larger;
if all the new digital product parameters are within the parameter threshold of the qualified products, modifying the production equipment parameters of the production stage after the semi-finished products of all the unqualified branch lines by referring to the main axis production equipment parameters;
if the new digital product parameters are not within the parameter threshold of the qualified product, continuing to trace back to the semi-finished product of the previous stage, modifying the production equipment parameters of the production stage after the semi-finished product is modified by referring to the main axis production equipment parameters, manufacturing the new digital product by the modified branch line, judging whether the new digital product parameters of the marked branch line are within the parameter threshold of the qualified product or not until all the new digital product parameters are within the parameter threshold of the qualified product.
Compared with the prior art, the invention has the following beneficial effects: in the process of designing and debugging equipment, a digital twin model of the production equipment is constructed by utilizing a digital twin technology, the data of the production and manufacturing stages in the life cycle of the product are integrally processed by utilizing the digital twin model, the data management efficiency and the data utilization rate are improved, the digital twin total model of the production line is constructed, unified debugging of the production lines in different states of the same type is realized, the state of the equipment and the digital twin model are synchronized by utilizing sensors and controllers arranged on the production line, so that a design developer can grasp and adjust the state of the equipment in real time, the data in the production process of each production line are uniformly stored and integrally managed according to the production flow, the design developer can grasp the process data of the production of the product, the problem in the production process of the product is discovered in time, different adjusting directions are selected according to the number of the production lines when the equipment is debugged, the work load of the system is saved, the adjusting time of the production line is reduced, the efficiency of the debugging production equipment is improved, and the design and the production efficiency of the life cycle of the product is improved.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention. In the drawings:
FIG. 1 is a schematic flow chart of a data integrated management system based on digital twin technology of the present invention;
FIG. 2 is a schematic diagram of steps of a method for integrated management of data based on digital twinning technology according to the present invention;
FIG. 3 is a flow chart of a digital twin model process in accordance with an embodiment of the present invention for a digital twin technology based data integration management system and method.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-2, the present invention provides the following technical solutions: the system comprises a product design digitizing module, a production and manufacturing equipment modeling module, a product difference judging module and a manufacturing adjusting module;
the product design digital module is used for designing an analog manufacturing process of processing raw materials into products, establishing a model of the raw materials and digital processing equipment and designing a processing flow; the product manufacturing equipment modeling module is used for collecting data of manufacturing equipment for manufacturing products, transmitting the equipment data in real time, constructing a digital twin model and adjusting the parameters of the manufacturing equipment according to the model; the product difference judging module is used for comparing the difference of products in the production process of different production lines and carrying out early warning on the production lines of which the products do not meet the requirements; the manufacturing adjustment module is used for tracing the processing reasons of the semi-finished products at the stage of overlarge difference, judging the specific scheme of adjusting production equipment, and judging whether to adjust the production environment, raw materials or design scheme;
the output end of the product design digitizing module is electrically connected with the input end of the product manufacturing equipment modeling module, the output end of the product manufacturing equipment modeling module is electrically connected with the input end of the product difference judging module, and the output end of the product difference judging module is electrically connected with the input end of the manufacturing adjusting module.
The product design digital module comprises a raw material model building unit, a digital processing equipment model building unit and a processing flow design unit; the raw material model building module is used for determining raw materials required by designing a product, acquiring data of the required raw materials and building a model; the digital processing equipment model building unit is used for obtaining original setting data of the product processing equipment and building a standard digital model of the processing equipment; the processing flow design unit is used for determining the processing flow of product manufacture according to the designed product, the needed raw materials and the processing equipment.
The product manufacturing equipment modeling module comprises a processing equipment data acquisition unit, a processing equipment data transmission unit and a processing equipment modeling simulation unit; the processing equipment data acquisition unit is used for acquiring real-time data and historical operation data of processing equipment on the production line; the processing equipment data transmission unit is used for transmitting processing equipment data and data between the digital twin model in real time; the processing equipment modeling simulation unit is used for establishing a digital twin model of the actual production equipment according to the original setting data, the real-time transmitted data of the actual processing equipment and the historical operation data.
The product difference judging module comprises a qualified product parameter threshold input unit, a difference judging unit and a data storage unit; the qualified product parameter threshold value input unit is used for inputting a parameter threshold value of a qualified product; the difference judging unit is used for judging whether the products of all the production lines are qualified or not, and marking and early warning the production lines of which the products do not meet the requirements; the data storage unit is used for data of the processing process of each digital twin model production line.
The manufacturing adjustment module comprises a difference cause tracing unit, an adjustment direction selection unit and an adjustment improvement unit; the difference cause tracing unit is used for tracing the causes of the product which do not meet the requirements; the adjusting direction selecting unit is used for selecting the adjusting direction of the production line of which the product is not in accordance with the requirement; the adjustment improvement unit is used for determining a specific scheme of adjustment.
A data integrated management method based on digital twin technology comprises the following steps:
s1, collecting data of raw materials and original setting data of processing equipment by a system, establishing a digital model of the raw materials and a theoretical digital model of the processing equipment, and determining a product processing flow;
s2, transmitting data to a system in real time by using a sensor on an actual production line, and establishing an actual digital twin model by combining theoretical digital model data, real-time transmitted operation data and historical operation data by using the system, wherein entity equipment on the actual production line is provided with the sensor and a controller;
s3, the actual digital twin model and the theoretical digital model are used for producing digital products by using the digital model of the raw materials, the processing steps in the manufacturing process of the raw materials and the products, the semi-finished products at each stage in the manufacturing process of the products of different production lines and the digital products of different production lines are marked, and the data are stored to generate a digital twin total model of the production line;
s4, inputting a data threshold value calibrated as a qualified product by a designer, screening out a disqualified product by a system, and tracing the processing steps of the disqualified product;
s5, analyzing reasons for unqualified products, and determining the improvement direction and the specific scheme.
In step S1, the system acquires geometric structure data and material parameter data of the raw materials, builds a digital model of the raw materials, acquires theoretical data originally set by the production equipment, builds a theoretical digital model of the processing equipment, acquires physical design data of the product, digitizes the physical design data, and then performs splitting of the processing steps to determine a flow of processing the product by the theoretical digital model.
The step S2 comprises the following specific steps:
s201, transmitting historical operation data and real-time state data to a system by an entity device sensor on a physical production line;
s202, a system obtains a theoretical digital model of processing equipment and historical running state data of entity equipment on a physical production line, and an actual digital twin model is constructed;
s203, the digital twin model corresponds to the sensor and the controller on the physical equipment on the physical production line, data acquired by the sensor on the physical equipment are transmitted to the digital twin model in real time, and the controller on the physical equipment modifies the parameters of the physical equipment while the parameters of the equipment in the digital twin model are modified.
The step S3 comprises the following specific steps:
s301, manufacturing digital products by a digital model and a digital twin model of each actual production line;
s302, storing and marking raw material data, processing step data in all digital product manufacturing processes, semi-finished product data at each stage in the product manufacturing process of different production lines and digital product data of different production lines;
s303, integrating the digital model and the digital twin models of all practical production lines to generate a production line digital twin total model, taking the production process of producing digital products by the digital model as a main axis, taking the production process of producing digital products by the digital twin models of the rest practical production lines as branch lines, and forming a new branch line by the difference of semi-finished product data in each production stage on the production line digital twin total model.
Dividing the production flow of the product into a plurality of stages according to the number of processing equipment, marking the product as one stage after each processing of one equipment from raw materials to finished products, and recording the data of the semi-finished products produced in the stage; recording all production processes of producing digital products by using a digital model, taking the production processes as a reference axis, sequentially recording production process data of producing the digital products by using a digital twin model of an actual production line, and judging the difference between semi-finished products of each stage of the digital twin model of the actual production line and semi-finished product data of each stage of a main axis from the processing of raw materials; if the difference value exceeds the difference range set by design manager, a branch line is separated from the node of the production stage, the data of the subsequent processing stage of the production line is recorded on the branch line, and the semi-finished product data and the difference value branch line are in direct proportion to the angle of the main axis; if the difference value does not exceed the difference range set by design manager, recording the semi-finished product data of the production stage of the production line and the semi-finished product data of the main axis together, and judging the data of the subsequent production stage until the production flow is finished; if the semi-finished product data of the next actual production line at the production stage and the data of one of the existing lines do not exceed the difference range set by design manager, recording the data of the two lines at the production stage together; and inputting all production process data of the digital twin model of the actual production line into a system.
The design of the processing flow of a new product is based on theoretical standard parameters of a production line, but equipment parameters on an actual production line are adjusted by the actual conditions of the previous production products, so that equipment and theoretical equipment of different actual production lines are different, equipment parameters in a digital model modeled by theoretical parameter standards are optimal data considering the production products at the beginning of the design, so that the digital twin model of other actual production lines are branch lines by taking the design as a main axis, the branch lines are compared with the main axis, the difference between the equipment parameters on the actual production line and the designed parameters can be seen at which production stages, the production equipment and the production flow corresponding to each data parameter of the product are respectively, and the adjusted reference direction can be obtained according to the main axis as a standard.
The digital twin total model integrates the production equipment data of all actual production lines, so that technicians can find out some outlier branch lines in time, problems can be found and adjusted, meanwhile, the data on the production lines are integrated, and the utilization rate of the data is increased.
In the steps S4-S5, the designer inputs the parameter threshold value of the qualified product, and judges whether the reason for producing the unqualified product is related to production equipment or not;
performing cluster analysis on the production environments of the qualified products and the unqualified products, and judging that the reason for producing the unqualified products is related to the production environment if the qualified products and the unqualified products are divided into two clusters;
if all the products cannot be qualified or the qualified products have irreproducibility, judging that the reason for producing the unqualified products is related to the raw materials or the design scheme, wherein the qualified products have the irreproducibility, namely that under the identical conditions, the processed products have qualified products and unqualified products, and no regularity exists;
if the qualified products can be processed by adjusting the equipment parameters of the production line of the unqualified products, and the reasons for producing the unqualified products are irrelevant to the production environment, the raw materials or the design scheme, judging that the reasons for producing the unqualified products are relevant to the production equipment;
if the reasons for producing the unqualified products are related to the production environment, raw materials or design schemes, modifying factors which lead to the unqualified products;
if the reasons for producing the unqualified products are related to production equipment, selecting in an improvement direction 1 and an improvement direction 2 according to the total number of production lines;
in the improvement direction 1, the system screens and marks all unqualified digital products, and for each unqualified digital product, according to a digital twin total model of a production line, the system traces back to a semi-finished product at the last stage from the digital product, and checks whether product parameters of other branch lines are within the parameter threshold of the qualified product at the production stage behind the semi-finished product;
if there is a branch line with the product parameter within the parameter threshold of the qualified product, modifying the production equipment parameter of the unqualified digital product at the production stage after the semi-finished product into the production equipment parameter of the branch line with the product parameter within the parameter threshold of the qualified product;
if no branch line with the product parameters within the parameter threshold value of the qualified product exists, tracing the semi-finished product to the semi-finished product in the last stage, checking whether the product parameters of other branch lines exist in the production stage behind the semi-finished product within the parameter threshold value of the qualified product or not until the product parameters of other branch lines exist in the production stage behind the traced semi-finished product within the parameter threshold value of the qualified product;
in the improvement direction 2, the system screens and marks partial unqualified digital products, for the unqualified digital products, tracing the digital products to the semi-finished products of the previous stage according to the digital twin total model of the production line, referring to the main axis production equipment parameters to modify the production equipment parameters of the production stage after the semi-finished products, manufacturing new digital products by the modified branch lines, judging whether the new digital product parameters of the marked branch lines are within the parameter threshold values of the qualified products;
if all the new digital product parameters are within the parameter threshold of the qualified products, modifying the production equipment parameters of the production stage after the semi-finished products of all the unqualified branch lines by referring to the main axis production equipment parameters;
if the new digital product parameters are not within the parameter threshold of the qualified product, continuing to trace back to the semi-finished product of the previous stage, modifying the production equipment parameters of the production stage after the semi-finished product is modified by referring to the main axis production equipment parameters, manufacturing the new digital product by the modified branch line, judging whether the new digital product parameters of the marked branch line are within the parameter threshold of the qualified product or not until all the new digital product parameters are within the parameter threshold of the qualified product.
Examples:
as shown in fig. 3, the product is marked D, the raw materials are marked A1, A2, A3, the processing equipment is marked B1, B2, B3, B4, the semi-finished products of each stage are marked C1, C2, C3, and the processing flow is divided into 4 stages.
When the production line digital twin total model is constructed according to the acquired data, raw materials A1, A2 and A3 are unchanged when the model simulates a processed product, actual equipment of each production line is marked as B1-1, B1-2, B1-3, B2-1 and the like, B1-1 represents processing equipment of a first stage of a production line with the serial number of 1, B2-1 represents processing equipment of a second stage of the production line with the serial number of 1, semi-finished products processed at each stage of each production line are marked as C1-1, C1-2, C1-3, C2-1 and the like, C1-1 represents semi-finished products processed at the first stage of the production line with the serial number of 1, C1-2 represents semi-finished products processed at the first stage of the production line with the serial number of 2, and products processed at each production line simulation are marked as D1, D2 and D3 and D1 represent products processed at the first stage of the production line with the serial number of 1.
Parameters of D1, D2 and D3 in dimension of product size are 55, 57 and 68 respectively, a qualified threshold value of a product input by design manager is 50 to 60, D3 is not satisfactory, as the production line of the D product is less, an improvement direction 1 is selected, the D3 is traced back to a semi-finished product B3-3 in the last production stage, after finding that the follow-up processed products D1 and D2 of the semi-finished products B3-1 and B3-2 in the same stage are qualified products, the follow-up equipment parameters of the production line with the serial number of 3 in the digital twin model are changed to be identical with the production line 1 or 2, and the corresponding controllers on the actual production line adjust the equipment parameters simultaneously.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: the foregoing description is only a preferred embodiment of the present invention, and the present invention is not limited thereto, but it is to be understood that modifications and equivalents of some of the technical features described in the foregoing embodiments may be made by those skilled in the art, although the present invention has been described in detail with reference to the foregoing embodiments. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. The utility model provides a data integration management system based on digital twin technique which characterized in that: the system comprises a product design digitizing module, a production and manufacturing equipment modeling module, a product difference judging module and a manufacturing adjusting module;
the product design digital module is used for designing an analog manufacturing process of a product processed by raw materials, establishing a model of the raw materials and digital processing equipment and designing a processing flow; the product manufacturing equipment modeling module is used for collecting data of production equipment for manufacturing products, transmitting the equipment data in real time, constructing a digital twin model and adjusting production equipment parameters according to the model; the product difference judging module is used for comparing the difference of products in the production process of different production lines and carrying out early warning on the production lines of which the products do not meet the requirements; the manufacturing adjustment module is used for tracing the processing reasons of the semi-finished products at the stage of overlarge difference, judging the specific scheme of adjusting production equipment, and judging whether to adjust the production environment, raw materials or design scheme;
the output end of the product design digitizing module is electrically connected with the input end of the product manufacturing equipment modeling module, the output end of the product manufacturing equipment modeling module is electrically connected with the input end of the product difference judging module, and the output end of the product difference judging module is electrically connected with the input end of the manufacturing adjusting module.
2. The integrated management system for data based on digital twinning technology according to claim 1, wherein:
the product design digitizing module comprises a raw material model building unit, a digital processing equipment model building unit and a processing flow design unit;
the raw material model building module is used for determining raw materials required by designing a product, acquiring data of the required raw materials and building a model;
the digital processing equipment model building unit is used for obtaining original setting data of the product processing equipment and building a standard digital model of the processing equipment;
the processing flow design unit is used for determining the processing flow of product manufacture according to the designed product, required raw materials and processing equipment.
3. The integrated management system for data based on digital twinning technology according to claim 1, wherein:
the product manufacturing equipment modeling module comprises a processing equipment data acquisition unit, a processing equipment data transmission unit and a processing equipment modeling simulation unit;
the processing equipment data acquisition unit is used for acquiring real-time data and historical operation data of processing equipment on the production line;
the processing equipment data transmission unit is used for transmitting processing equipment data and data between the digital twin model in real time;
the processing equipment modeling simulation unit is used for establishing a digital twin model of the actual production equipment according to the original setting data, the real-time transmitted data of the actual processing equipment and the historical operation data.
4. The integrated management system for data based on digital twinning technology according to claim 1, wherein:
the product difference judging module comprises a qualified product parameter threshold input unit, a difference judging unit and a data storage unit;
the qualified product parameter threshold value input unit is used for inputting a parameter threshold value of a qualified product;
the difference judging unit is used for judging whether the products of all production lines are qualified or not, and marking and early warning the production lines of which the products do not meet the requirements;
the data storage unit is used for data of the production line processing process of each digital twin model.
5. The integrated management system for data based on digital twinning technology according to claim 1, wherein:
the manufacturing adjustment module comprises a difference cause tracing unit, an adjustment direction selection unit and an adjustment improvement unit;
the difference cause tracing unit is used for tracing the causes of the product which do not meet the requirements;
the adjusting direction selecting unit is used for selecting the adjusting direction of the production line of which the product is not in accordance with the requirement;
the adjustment improvement unit is used for determining a specific scheme of adjustment.
6. A data integrated management method based on a digital twin technology is characterized by comprising the following steps of: the method comprises the following steps:
s1, collecting data of raw materials and original setting data of processing equipment by a system, establishing a digital model of the raw materials and a theoretical digital model of the processing equipment, and determining a product processing flow;
s2, transmitting data to a system in real time by using a sensor on an actual production line, and establishing an actual digital twin model by combining theoretical digital model data, real-time transmitted operation data and historical operation data by using the system, wherein entity equipment on the actual production line is provided with the sensor and a controller;
s3, the actual digital twin model and the theoretical digital model are used for producing digital products by using the digital model of the raw materials, the processing steps in the manufacturing process of the raw materials and the products, the semi-finished products at each stage in the manufacturing process of the products of different production lines and the digital products of different production lines are marked, and the data are stored to generate a digital twin total model of the production line;
s4, inputting a data threshold value calibrated as a qualified product by a designer, screening out a disqualified product by a system, and tracing the processing steps of the disqualified product;
s5, analyzing reasons for unqualified products, and determining the improvement direction and the specific scheme.
7. The integrated management method for data based on digital twin technology as defined in claim 6, wherein:
in step S1, the system acquires geometric structure data and material parameter data of the raw materials, builds a digital model of the raw materials, acquires theoretical data originally set by the production equipment, builds a theoretical digital model of the processing equipment, acquires physical design data of the product, digitizes the physical design data, and then performs splitting of the processing steps to determine a flow of processing the product by the theoretical digital model.
8. The integrated management method for data based on digital twin technology as defined in claim 6, wherein:
the step S2 comprises the following specific steps:
s201, transmitting historical operation data and real-time state data to a system by an entity device sensor on a physical production line;
s202, a system obtains a theoretical digital model of processing equipment and historical running state data of entity equipment on a physical production line, and an actual digital twin model is constructed;
s203, the digital twin model corresponds to the sensor and the controller on the physical equipment on the physical production line, data acquired by the sensor on the physical equipment are transmitted to the digital twin model in real time, and the controller on the physical equipment modifies the parameters of the physical equipment while the parameters of the equipment in the digital twin model are modified.
9. The integrated management method for data based on digital twin technology as defined in claim 6, wherein:
the step S3 comprises the following specific steps:
s301, manufacturing digital products by a digital model and a digital twin model of each actual production line;
s302, storing and marking raw material data, processing step data in all digital product manufacturing processes, semi-finished product data at each stage in the product manufacturing process of different production lines and digital product data of different production lines;
s303, integrating the digital model and the digital twin model of each actual production line to generate a production line digital twin total model, taking the production process of producing digital products by the digital model as a main axis, taking the production process of producing digital products by the digital twin model of the other actual production lines as a branch line, and forming a new branch line by the difference of semi-finished product data in each production stage on the production line digital twin total model;
dividing the production flow of the product into a plurality of stages according to the number of processing equipment, marking the product as one stage after each processing of one equipment from raw materials to finished products, and recording the data of the semi-finished products produced in the stage; recording all production processes of producing digital products by using a digital model, taking the production processes as a reference axis, sequentially recording production process data of producing the digital products by using a digital twin model of an actual production line, and judging the difference between semi-finished products of each stage of the digital twin model of the actual production line and semi-finished product data of each stage of a main axis from the processing of raw materials; if the difference value exceeds the difference range set by design manager, a branch line is separated from the node of the production stage, the data of the subsequent processing stage of the production line is recorded on the branch line, and the semi-finished product data and the difference value branch line are in direct proportion to the angle of the main axis; if the difference value does not exceed the difference range set by design manager, recording the semi-finished product data of the production stage of the production line and the semi-finished product data of the main axis together, and judging the data of the subsequent production stage until the production flow is finished; if the semi-finished product data of the next actual production line at the production stage and the data of one of the existing lines do not exceed the difference range set by design manager, recording the data of the two lines at the production stage together; and inputting all production process data of the digital twin model of the actual production line into a system.
10. The integrated management method for data based on digital twin technology as defined in claim 6, wherein:
in the steps S4-S5, the designer inputs the parameter threshold value of the qualified product, and judges whether the reason for producing the unqualified product is related to production equipment or not;
performing cluster analysis on the production environments of the qualified products and the unqualified products, and judging that the reason for producing the unqualified products is related to the production environment if the qualified products and the unqualified products are divided into two clusters;
if all the products cannot be qualified or the qualified products have irreproducibility, judging that the reason for producing the unqualified products is related to the raw materials or the design scheme, wherein the qualified products have the irreproducibility, namely that under the identical conditions, the processed products have qualified products and unqualified products, and no regularity exists;
if the qualified products can be processed by adjusting the equipment parameters of the production line of the unqualified products, and the reasons for producing the unqualified products are irrelevant to the production environment, the raw materials or the design scheme, judging that the reasons for producing the unqualified products are relevant to the production equipment;
if the reasons for producing the unqualified products are related to the production environment, raw materials or design schemes, modifying factors which lead to the unqualified products;
if the reasons for producing the unqualified products are related to the production equipment, the selection is performed according to the total number of the production lines.
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