CN115291561B - Manufacturing system, equipment virtual debugging platform, method, equipment and application - Google Patents

Abstract

The invention belongs to the technical field of simulation data processing in a manufacturing system, and discloses a manufacturing system, equipment virtual debugging platform, method, equipment and application. The platform comprises: the system comprises a physical entity control unit, a virtual control unit, a data transmission middleware, a virtual manufacturing system operation environment unit, an intelligent manufacturing information management and execution system and a system operation visualization interaction module. According to the invention, the planned optimal result is output through the virtual control unit revising program, and the high-speed and faithful mapping of the data, the model, the algorithm and the program between the virtual debugging and the actual operation is established, so that the intelligent upgrading, reconstruction and application of the manufacturing system and equipment can be realized more efficiently. By combining with the digital twin theory, the manufacturing system and equipment virtual debugging system platform and the building method of the digital twin drive provided by the invention respond to debugging requirements in multiple fields and multiple rings and improve the debugging effect.

Description

A manufacturing system and equipment virtual debugging platform, method, device and application

Technical Field

The present invention belongs to the technical field of simulation data processing in manufacturing systems, and in particular relates to a manufacturing system and equipment virtual debugging platform, method, device and application.

Background technique

Under the background of intelligent manufacturing, the manufacturing industry is developing from digitalization to intelligence. As the core subjects of manufacturing activities, the improvement of the intelligent capabilities of manufacturing systems and equipment has attracted the attention of more and more manufacturing companies.

In the process of enterprises upgrading traditional workshops to smart ones, existing systems need to be upgraded or replaced. However, due to the dual requirements of cost control and system performance improvement, before the system upgrade, the operating procedures and dynamic coordination parameters of the current manufacturing system and equipment need to be tested and optimized to ensure the safe and reliable operation of manufacturing activities. This leads to the problem of continuously increasing costs and long cycles in the actual manufacturing system upgrade process.

Through the above analysis, the problems and defects of the existing technology are as follows: the common method to solve the debugging problem is virtual debugging, but the traditional virtual debugging process has problems such as poor visualization of the debugging process, inconsistent information between the virtual model and the physical equipment, and separation from the actual manufacturing activities. As a result, the debugging results are unreliable and cannot directly guide production. They need to be verified through further actual debugging. Therefore, there is an urgent need for a virtual debugging system platform with high simulation of virtual models of manufacturing systems and equipment.

Summary of the invention

In order to overcome the problems existing in the related art, the embodiments disclosed in the present invention provide a manufacturing system and equipment virtual debugging platform, method, device and application. The purpose of the present invention is to provide a manufacturing system and equipment virtual debugging system platform and control method driven by digital twins to improve the authenticity of virtual debugging and the reliability of debugging results.

The technical solution is as follows: a manufacturing system and equipment virtual debugging platform driven by digital twins, characterized in that the manufacturing system and equipment virtual debugging platform driven by digital twins includes:

The physical entity control unit is used to actually run the physical control logic and send motion control instructions, production process operation signals, and status instructions to the data transmission middleware; and receive simulated sensor signals and production process instructions fed back by the data transmission middleware;

The virtual control unit is connected to the data transmission middleware and is used for high-simulation virtual debugging. It also builds the virtual logic for event processing in the production process by faithfully mapping the physical control logic, so that the program format of the virtual and real space is consistent. It is also used to send motion control instructions to the data transmission middleware and receive virtual simulation signals fed back by the data transmission middleware.

Data transmission middleware, used to achieve cross-protocol, multi-granular data integration, and support the operation of the virtual commissioning platform through database integration and functional data model definition;

The virtual manufacturing system operating environment unit is connected to the data transmission middleware and is used to send simulation sensor signals to the data transmission middleware and receive motion control instructions fed back by the data transmission middleware through the twin models of the manufacturing system and equipment entities, the production environment element models under actual working conditions, the algorithm model oriented to the production goal, and the behavior interface model of multi-model collaboration;

Intelligent manufacturing information management and execution system, connected with data transmission middleware, is used to support system data management and operation status monitoring through data management analysis and Web front-end data display;

Sending production process instructions to the data transmission middleware and receiving production status data from the data transmission middleware;

The system runs a visualization interaction module, which is connected to the virtual manufacturing system operating environment unit for user interaction, sending parameter adjustment data to the virtual manufacturing system operating environment unit, and receiving simulation data sent by the virtual manufacturing system operating environment unit.

In one embodiment, the physical entity control unit includes: a PLC, a main numerical control system, a robot controller, and an environmental data sensing unit;

The PLC is used to receive signals transmitted by the environmental data sensing unit and send general operation control instructions to the main numerical control system, the robot controller and the environmental data sensing unit;

The main numerical control system is used to control the operating status of the machine tool;

The robot controller is used to control the operating state of the robot;

The environmental data perception unit is used to collect and integrate the actual working conditions of machine tools and robots.

In one embodiment, the virtual control unit includes: a virtual numerical control system, a PLC virtual programming environment system, a robot virtual controller and a production process event processor, which respectively control the operating status of the machine tool twin, process control twin, robot twin and production process event twin in the virtual environment.

In one embodiment, the virtual manufacturing system operating environment unit includes: a twin model module of the manufacturing system and the equipment entity, a production environment element model module under actual working conditions, an algorithm model module oriented to production goals, and a behavior interface model module for multi-model collaboration;

The twin model module of the manufacturing system and equipment entity is used to realize the visual representation of the actual operating environment through the behavior model of production factors under complex working conditions;

The production environment element model module under actual working conditions is used to achieve a virtual description of the actual production process through a behavior model of the environment under complex working conditions;

The production-oriented algorithm model module is used to establish a multi-objective algorithm library to optimize the debugging process;

The multi-model collaborative behavior interface model module is used for multi-source heterogeneous information perception and integrated interaction under complex heterogeneous time-varying working conditions to achieve plug-and-play data sharing.

In one embodiment, the intelligent manufacturing information management and execution system includes: a data management and analysis module and a Web front-end data display module;

The data management and analysis module is used to realize data integration and collection of the debugging platform through the database of the information management system;

The WEB front-end data display module is used to display two-dimensional data, form an intuitive data statistical analysis function, and deliver it to the client.

Another object of the present invention is to provide a control method for realizing the manufacturing system and equipment virtual debugging platform driven by the digital twin, and the manufacturing system and equipment virtual debugging control method driven by the digital twin comprises the following steps:

S1, runs the production logic through the physical entity control unit and the virtual control unit, and transmits the motion control instructions of the manufacturing system and equipment, the operating status of the production process, and the signal translation to the virtual manufacturing system operating environment unit through the data transmission middleware;

S2, adjusts the control logic of the embedded virtual control unit through the feedback simulation parameters;

S3, ultimately forming a manufacturing system and equipment upgrade and production plan that meets actual production conditions.

Another object of the present invention is to provide a computer device, characterized in that the computer device includes a memory and a processor, the memory stores a computer program, and when the computer program is executed by the processor, the processor executes the digital twin-driven manufacturing system and equipment virtual debugging control method.

Another object of the present invention is to provide a computer-readable storage medium storing a computer program, which, when executed by a processor, enables the processor to execute the digital twin-driven manufacturing system and equipment virtual debugging control method.

Another object of the present invention is to provide an application of the digital twin-driven manufacturing system and equipment virtual debugging platform in the simulation of disassembly and assembly of manufacturing equipment components.

Another object of the present invention is to provide an application of the digital twin-driven manufacturing system and equipment virtual debugging platform in student practical training teaching and innovation competition virtual simulation.

Combining all the above technical solutions, the advantages and positive effects of the present invention are as follows:

First, in view of the technical problems existing in the above-mentioned prior art and the difficulty of solving the problems, the technical solutions to be protected by the present invention and the results and data during the research and development process are closely combined to analyze in detail and deeply how the technical solutions of the present invention solve the technical problems, and some creative technical effects brought about after solving the problems, which are specifically described as follows:

The present invention builds production scenarios of manufacturing systems and equipment under actual working conditions through the digital twin model modeling environment of the manufacturing unit, and establishes a mapping relationship between the physical controller and the twin space through the data middleware and the intelligent manufacturing information management and execution system, thereby reducing the design difficulty of the system control model and the production event description model. At the same time, it can more realistically reflect the actual operating status of the manufacturing system and equipment, greatly improving the authenticity of virtual debugging.

The present invention builds manufacturing systems and equipment and their operating environment based on digital twins, and uses a virtual debugging method in which the hardware and software control systems are in the loop. Compared with traditional virtual debugging methods, this method provides a highly realistic digital twin-driven virtual debugging method.

The present invention can more efficiently realize the intelligent upgrading and application of manufacturing systems and equipment by revising the program output of the optimal planning result through the virtual control unit, establishing a high-speed and faithful mapping of data, models, algorithms and programs between virtual debugging and actual operations.

Second, considering the technical solution as a whole or from the perspective of the product, the technical effects and advantages of the technical solution to be protected by the present invention are described in detail as follows:

In combination with the digital twin theory, the present invention provides a digital twin-driven manufacturing system and equipment virtual debugging system platform and construction method to respond to debugging needs in multiple fields and environments and improve debugging effects.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

FIG1 is a schematic diagram of a manufacturing system and equipment virtual debugging platform driven by a digital twin according to an embodiment of the present invention;

2 is a flow chart of a control method for a manufacturing system and equipment virtual debugging platform driven by a digital twin according to an embodiment of the present invention;

3 is a schematic diagram of the operation of a digital twin-driven manufacturing system and equipment virtual debugging platform provided in an embodiment of the present invention;

4 is a schematic diagram of the operation principle of the intelligent manufacturing information management and execution system provided by an embodiment of the present invention;

5 is a schematic diagram of the application scenario of a digital twin-driven manufacturing system and equipment virtual debugging platform provided in an embodiment of the present invention;

In the figure: 1. Physical entity control unit; 1-1. PLC; 1-2. Main CNC system; 1-3. Robot controller; 1-4. Environmental data perception unit; 2. Virtual control unit; 2-1. Virtual CNC system; 2-2. PLC virtual programming environment system; 2-3. Robot virtual controller; 2-4. Production process event processor; 3. Data transmission middleware; 4. Manufacturing system operating environment unit; 4-1. Twin model module of manufacturing system and equipment entity; 4-2. Production environment element model module under actual working conditions; 4-3. Algorithm model module for production goals; 4-4. Behavioral interface model module for multi-model collaboration; 5. Intelligent manufacturing information management and execution system; 5-1. Data management and analysis module; 5-2. Web front-end data display module; 6. System operation visualization interaction module.

Detailed ways

In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present invention, so the present invention is not limited by the specific implementation disclosed below.

1. Explanation of the embodiment:

Example 1

As shown in FIG1 , the digital twin-driven manufacturing system and equipment virtual debugging platform provided in an embodiment of the present invention includes: a physical entity control unit 1, a virtual control unit 2, a data transmission middleware 3, a manufacturing system operating environment unit 4, an intelligent manufacturing information management and execution system 5, and a system operation visualization interaction module 6;

By building a physical entity control unit 1 and a virtual control unit 2 in a virtual debugging system, highly realistic virtual debugging can be achieved.

In the embodiment of the present invention, the physical entity control unit 1 includes a PLC 1-1, a main numerical control system 1-2, a robot controller 1-3 and an environmental data perception unit 1-4, which actually runs the physical control logic.

The PLC 1-1 is used to receive signals transmitted by the environmental data sensing unit 1-4 and send general operation control instructions to the main numerical control system 1-2 and the robot controller 1-3;

The main CNC system 1-2 is used to control the operating status of the machine tool;

The robot controller 1-3 is used to control the operation status of the robot;

Environmental data sensing units 1-4 are used to integrate and collect the actual working conditions of machine tools and robots.

The environmental data sensing units 1-4 include but are not limited to RFID and sensors;

In an embodiment of the present invention, the virtual control unit 2 includes a virtual numerical control system 2-1, a PLC virtual programming environment system 2-2, a robot virtual controller 2-3 and a production process event processor 2-4, which respectively control the operating status of the machine tool twin, process control twin, robot twin and production process event twin in the virtual environment; by faithfully mapping the physical control logic, a virtual logic for production process event processing is built to ensure the consistency of the program format running in the virtual and real spaces.

In an embodiment of the present invention, the data transmission middleware 3 implements cross-protocol, multi-granularity data integration to address the problem of incompatibility of data transmission protocols between software and hardware control systems and sensing devices from different manufacturers, and supports the efficient operation of the virtual debugging platform through database integration and functional data model definition.

The virtual manufacturing system operating environment unit 4 is a twin model of the actual manufacturing system, including a twin model module 4-1 of the manufacturing system and equipment entity, a production environment element model module 4-2 under actual working conditions, an algorithm model module 4-3 oriented to production goals, and a multi-model collaborative behavior interface model module 4-4.

The twin model module 4-1 of the manufacturing system and equipment entity is used to realize the visual representation of the actual operating environment through the behavioral model of production factors under complex working conditions;

The production environment factor model module 4-2 under actual working conditions is used to achieve a virtual description of the actual production process through a behavior model of the environment under complex working conditions;

The production-oriented algorithm model module 4-3 is used to establish a multi-objective algorithm library to optimize the debugging process;

The multi-model collaborative behavior interface model module 4-4 is used for multi-source heterogeneous information perception and integrated interaction under complex heterogeneous time-varying working conditions to achieve plug-and-play data sharing.

The intelligent manufacturing information management and execution system 5 includes a data management and analysis module 5-1 and a Web front-end data display module 5-2, which support the data management and operation status monitoring of the system.

The data management and analysis module 5-1 is used to realize data integration and collection of the debugging platform through the database of the information management system;

The WEB front-end data display module 5-2 is used to display two-dimensional data, form an intuitive data statistical analysis function, and deliver it to the client.

The system runs a visualization interaction module 6 for user interaction.

Example 2

As shown in FIG2 , the manufacturing system and equipment virtual debugging platform control method driven by digital twins provided in an embodiment of the present invention includes:

S101, the physical entity control unit 1 and the virtual control unit 2 run the production logic, and the motion control instructions of the manufacturing system and equipment, the production process operation status, and the signal translation are transmitted to the virtual manufacturing system operation environment unit 4 through the data transmission middleware 3;

S102, adjusting the control logic of the embedded virtual control unit 2 through the feedback simulation parameters;

S103, ultimately forming a manufacturing system and equipment upgrade and production plan that meets actual production conditions.

In an embodiment of the present invention, as shown in Figure 3, the operating principle of the digital twin-driven manufacturing system and equipment virtual debugging platform provided by the embodiment of the present invention is provided; as shown in Figure 4, the operating principle of the intelligent manufacturing information management and execution system provided by the embodiment of the present invention is provided.

In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described or recorded in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

Since the information interaction, execution process, etc. between the above-mentioned devices/units are based on the same concept as the method embodiment of the present invention, their specific functions and technical effects can be found in the method embodiment part and will not be repeated here.

Those skilled in the art can clearly understand that, for the convenience and simplicity of description, only the division of the above-mentioned functional units and modules is used as an example for illustration. In practical applications, the above-mentioned function allocation can be completed by different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiment can be integrated in a processing unit, or each unit can exist physically separately, or two or more units can be integrated in one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of software functional units. In addition, the specific names of the functional units and modules are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention. The specific working process of the units and modules in the above-mentioned system can refer to the corresponding process in the aforementioned method embodiment, which will not be repeated here.

2. Application examples:

Application Example 1

As shown in Figure 5, the digital twin-driven manufacturing system and equipment virtual debugging platform provided by the embodiment of the present invention can be applied in actual scenarios.

Application Example 2

An application embodiment of the present invention also provides a computer device, which includes: at least one processor, a memory, and a computer program stored in the memory and executable on the at least one processor, wherein the processor implements the steps in the above-mentioned digital twin-driven manufacturing system and equipment virtual debugging platform control method embodiment when executing the computer program.

Example 3

An application embodiment of the present invention also provides a computer-readable storage medium, which stores a computer program. When the computer program is executed by a processor, it can implement the steps in the above-mentioned digital twin-driven manufacturing system and equipment virtual debugging platform control method embodiment.

Example 4

An application embodiment of the present invention also provides an information data processing terminal, which is used to provide a user input interface to implement the steps in the above-mentioned digital twin-driven manufacturing system and equipment virtual debugging platform control method embodiment when executed on an electronic device. The information data processing terminal is not limited to mobile phones, computers, and switches.

Example 5

An application embodiment of the present invention also provides a server, which is used to provide a user input interface to implement the steps in the above-mentioned digital twin-driven manufacturing system and equipment virtual debugging platform control method embodiment when executed on an electronic device.

Application Example 6

An embodiment of the present invention provides a computer program product. When the computer program product runs on an electronic device, the electronic device can implement the steps in the above-mentioned digital twin-driven manufacturing system and equipment virtual debugging platform control method embodiment when executing.

If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the present invention implements all or part of the processes in the above-mentioned embodiment method, which can be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a computer-readable storage medium. When the computer program is executed by the processor, the steps of the above-mentioned method embodiments can be implemented. Among them, the computer program includes computer program code, and the computer program code can be in source code form, object code form, executable file or some intermediate form. The computer-readable medium may at least include: any entity or device that can carry the computer program code to the camera device/terminal device, recording medium, computer memory, read-only memory (ROM), random access memory (RAM), electric carrier signal, telecommunication signal and software distribution medium. For example, a USB flash drive, a mobile hard disk, a disk or an optical disk.

The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by any technician familiar with the technical field within the technical scope disclosed by the present invention and within the spirit and principles of the present invention should be covered within the protection scope of the present invention.

Claims (10)

1. A digital twinned manufacturing system and equipment virtual debugging platform, the digital twinned manufacturing system and equipment virtual debugging platform comprising:

The physical entity control unit (1) is used for actually running the physical control logic and sending a motion control instruction, a production process running signal and a state instruction to the data transmission middleware (3); receiving simulation sensor signals and production flow instructions fed back by the data transmission middleware (3);

the virtual control unit (2) is connected with the data transmission middleware (3) and is used for performing virtual debugging with high simulation performance, and building event processing virtual logic in the production process through faithfully mapping physical control logic so as to enable the running program format of the virtual space to be consistent; the virtual simulation system is also used for sending motion control instructions to the data transmission middleware (3) and receiving virtual simulation signals fed back by the data transmission middleware (3);

the data transmission middleware (3) is used for realizing cross-protocol and multi-granularity data integration, and supporting the operation of the virtual debugging platform through database integration and functional data model definition;

The virtual manufacturing system operation environment unit (4) is connected with the data transmission middleware (3) and is used for sending simulation sensor signals to the data transmission middleware (3) and receiving motion control instructions fed back by the data transmission middleware (3) through a provided twin model of a manufacturing system and equipment entity, a production environment element model under actual working conditions, a production target-oriented algorithm model and a multi-model collaborative behavior interface model;

the intelligent manufacturing information management and execution system (5) is connected with the data transmission middleware (3) and is used for data management and operation state monitoring of the support system through data management analysis and Web front-end data display;

Sending a production flow instruction to the data transmission middleware (3) and receiving production state data sent by the data transmission middleware (3);

The system operation visualization interaction module (6) is connected with the virtual manufacturing system operation environment unit (4) and used for user interaction, parameter adjustment data sent to the virtual manufacturing system operation environment unit (4) and simulation data sent by the virtual manufacturing system operation environment unit (4) are received.

2. The digital twin-drive manufacturing system and equipment virtual debugging platform according to claim 1, wherein the physical entity control unit (1) comprises: the system comprises a PLC (1-1), a main numerical control system (1-2), a robot controller (1-3) and an environment data sensing unit (1-4);

The PLC (1-1) is used for receiving signals transmitted by the environment data sensing unit (1-4) and sending operation total control instructions to the main numerical control system (1-2), the robot controller (1-3) and the environment data sensing unit (1-4);

The main numerical control system (1-2) is used for controlling the running state of the machine tool;

the robot controller (1-3) is used for controlling the running state of the robot;

the environment data sensing unit (1-4) is used for collecting and integrating the actual working condition and the running condition of the machine tool and the robot.

3. The digital twin-drive manufacturing system and equipment virtual debugging platform according to claim 1, characterized in that the virtual control unit (2) comprises: the system comprises a virtual numerical control system (2-1), a PLC virtual programming environment system (2-2), a robot virtual controller (2-3) and a production process event processor (2-4), wherein the running states of a machine tool twin, a process control twin, a robot twin and a production process event twin in the virtual environment are controlled respectively.

4. The digital twin-drive manufacturing system and equipment virtual debugging platform according to claim 1, wherein the virtual manufacturing system work environment unit (4) comprises: a twin model module (4-1) of a manufacturing system and equipment entity, a production environment element model module (4-2) under actual working conditions, an algorithm model module (4-3) facing production targets and a behavior interface model module (4-4) with multi-model cooperation;

The twin model module (4-1) of the manufacturing system and the equipment entity is used for realizing the visual representation of the actual running environment through the behavior model of the production element under the complex working condition;

the production environment element model module (4-2) under the actual working condition is used for realizing the actual production process of the simulated description through the behavior model of the environment under the complex working condition;

the production-target-oriented algorithm model module (4-3) is used for optimizing a debugging process by the established multi-target algorithm library;

The multi-model collaborative behavior interface model module (4-4) is used for realizing plug and play type data sharing aiming at multi-source heterogeneous information perception and integration interaction under complex heterogeneous time-varying working conditions.

5. The digital twin-driven manufacturing system and equipment virtual debugging platform according to claim 1, characterized in that the intelligent manufacturing information management and execution system (5) comprises: the system comprises a data management analysis module (5-1) and a Web front-end data display module (5-2);

the data management analysis module (5-1) is used for realizing data integration and collection of the debugging platform through a database of the information management system;

The WEB front-end data display module (5-2) is used for displaying two-dimensional data, forming an intuitive data statistics analysis function and delivering the visual data statistics analysis function to the client.

6. A control method for implementing the digital twin-drive manufacturing system and equipment virtual debugging platform according to any one of claims 1-5, characterized in that the digital twin-drive manufacturing system and equipment virtual debugging control method comprises the following steps:

S1, running production logic through a physical entity control unit (1) and a virtual control unit (2), and translating and transmitting motion control instructions and production process running states and signals of a manufacturing system and equipment to a virtual manufacturing system operation environment unit (4) through a data transmission middleware (3);

S2, adjusting the control logic of the embedded virtual control unit (2) through the feedback simulation parameters;

And S3, finally forming a manufacturing system and equipment upgrading and production scheme which meet the actual production working conditions.

7. A computer device comprising a memory and a processor, the memory storing a computer program that, when executed by the processor, causes the processor to perform the digital twinned drive manufacturing system and equipment virtual debug control method of claim 6.

8. A computer readable storage medium storing a computer program which, when executed by a processor, causes the processor to perform the digital twinned drive manufacturing system and equipment virtual debug control method of claim 6.

9. A method of using the digital twinned drive manufacturing system and equipment virtual debug platform of any of claims 1-5 in manufacturing equipment component disassembly simulation.

10. A method for applying the digital twin-drive manufacturing system and equipment virtual debugging platform according to any one of claims 1-5 to student practical training teaching and innovation competition virtual simulation.