General assembly process virtual-real mapping method and monitoring system of digital twin workshop

Abstract

The invention discloses a general assembly process virtual-real mapping method of a digital twin workshop and a monitoring system. The method comprises the following steps: S1, acquiring various production data in a final assembly process of a packaging workshop based on an OPC UA protocol and transmitting the data in real time; s2, constructing a behavior logic model based on a Petri network to describe a virtual entity motion rule; s3, constructing a 3D digital twin workshop model subjected to lightweight processing; s4, analyzing and decomposing complex behaviors of the production equipment, and cooperating with overall operation and control; and S5, simulation is carried out in the Unity 3D engine, and real-time driving and monitoring are realized. Wherein the data preprocessing comprises format unification, data screening and classified induction; real-time transmission relates to OPC UA client / server connection, and data is distributed to a database and Unity 3D; real-time driving is achieved by dividing motion data according to frames and calling motion scripts frame by frame. The system comprises a data module, a modeling module, a motion module and a driving module. The problems of model redundancy and system load are solved, and transparent, efficient and intelligent management of a production field is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of digital twin technology, and in particular, to a virtual-real mapping method and a monitoring system for the general assembly process of a digital twin workshop. Background Art

[0002] With the rapid development of modern technology, digital twin technology has become a key bridge connecting the physical world and the information world, and is widely regarded internationally as the core element for achieving the deep integration of digital information and physical entities. Through precise measurement, advanced simulation technology, and data analysis, this technology constructs a virtual mapping model corresponding to physical entity devices in a virtual environment, enabling real-time monitoring, efficient processing, and accurate prediction of the operating states of physical entities. In addition, through signal instructions such as scripts, digital twin technology can also perform intelligent optimization and adjustment on entity devices in the physical space, significantly improving the operating efficiency and intelligence level of the devices.

[0003] In view of the above advantages, digital twin technology provides a new idea for the three-dimensional visual monitoring of packaging workshops, effectively promoting the development of intelligent workshops towards digitalization and networking, and has initially realized transparent, efficient, and intelligent management of the production workshop site in practical applications.

[0004] However, when existing digital twin technology is applied to the monitoring of complex production workshops, the following problems still exist: Due to the large number of resources in the workshop, if precise modeling is carried out for all resources, it will lead to model redundancy. This redundancy will not only significantly increase the system load but also extend the system operation delay, thereby reducing the efficiency and response speed of the overall monitoring system. Therefore, in practical applications, it is not always the optimal choice to perform undifferentiated and comprehensive modeling for all workshop equipment. Existing technologies have not fully considered targeted production monitoring of specific equipment to effectively reduce the load of the workshop monitoring system. This limits the maximum utility of digital twin technology in large and complex production workshops, especially for the precise monitoring requirements of single or a few key equipment that need to be focused on. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a virtual-real mapping method and a monitoring system for the general assembly process of a digital twin workshop, which monitor the general assembly process of a packaging workshop, realize virtual-real mapping through the powerful physical engine of Unity3D, and perform real-time and precise simulation and real-time monitoring of the on-site operation of industrial robot assembly, so as to improve the monitoring efficiency and accuracy.

[0006] To solve the above technical problems, the technical solution of the present invention is: A virtual-real mapping method for the general assembly process of a digital twin workshop, comprising the following steps: S1: Collect various production data during the general assembly process in the packaging workshop based on the industrial communication protocol OPC UA, encapsulate the collected data in a unified format and perform multi-source data classification and preprocessing, and transmit the preprocessed data in real-time through network communication to provide the motion data required for virtual entity motion control and the multi-source data required for visualization; the various production data include the environmental information, material information, production equipment information determined before production, and the equipment status information generated during the production process; S2: Analyze the production status and production behaviors of the overall work process in the packaging workshop, and construct a behavior logic model based on Petri nets according to the mapping rules to describe the motion rules during the general assembly process of the virtual entity; S3: Construct a 3D digital twin workshop corresponding to the real workshop, where the packaging machine model in the 3D digital twin workshop is lightweight processed; S4: Analyze the complex production behaviors of the production equipment in the digital twin workshop, decompose the motion actions of each equipment component according to the relationships between the production equipment, and perform overall motion control coordination to complete the drive of the equipment; S5: Based on the behavior logic model, the real-time transmitted data, and the decomposition of the complex production behaviors of the production equipment, conduct a simulation experiment in the Unity3D engine to achieve real-time drive and monitoring of the digital twin workshop.

[0007] To implement the above technical solution, first, through step S1, various production data during the general assembly process in the packaging workshop are collected and transmitted in real time based on the industrial communication protocol OPC UA, including the environmental information, material information, production equipment information determined before production, and the equipment status information generated during the production process, thereby providing necessary data support for the motion control and visualization of virtual entities. Secondly, in step S2, the production status and production behavior of the overall work process are analyzed, and a behavior logic model based on Petri nets is constructed according to the mapping rules to formally describe the motion rules of virtual entities during the general assembly process. Subsequently, through step S3, a 3D digital twin workshop corresponding to the real workshop is constructed, and the packaging machine model therein is lightweighted to ensure the performance optimization of the virtual model. Furthermore, in step S4, the complex behaviors of production equipment are analyzed and decomposed to realize the motion action decomposition of each equipment component and the overall motion control cooperation, and the precise drive of the equipment is completed. Finally, in step S5, based on the above behavior logic model, real-time transmitted data, and complex behavior decomposition, a simulation experiment is carried out in the Unity3D engine, and then the real-time drive and monitoring of the digital twin workshop are realized. The accurate and real-time virtual-real mapping of the general assembly process of the physical packaging workshop to the virtual digital twin environment is achieved. The technical effect is that it can significantly improve the monitoring efficiency and accuracy of the general assembly process in the packaging workshop, realize the transparent, efficient, and intelligent management of the production site through real-time data drive, and effectively solve the problems of model redundancy and system load that may exist in traditional modeling, thereby optimizing the operation performance of the overall system.

[0008] As a preferred embodiment of the present invention, step S2 specifically includes: according to the production status and production behavior of the overall work process in the packaging workshop, abstracting the production status as the places of Petri nets and the production behavior as the transitions of Petri nets; the places include the places representing the preparation action status of each system of the packaging machine and the places representing the completion status of each system action of the packaging machine; the transitions include the transitions when the parts to be processed enter different packaging nodes and the transitions representing the buffer conveyor belts of production nodes.

[0009] By accurately transforming the actual production process into the behavior logic model of Petri nets, the present invention can clearly and intuitively display each link of the packaging production, and deeply analyze the processing logic and technological process of the workshop. This accurate behavior model provides a basis for the dynamic and accurate mapping of the assembly production line site for the digital twin monitoring system, so that the motion behavior of the virtual model is highly consistent with the real operation of the physical entity, laying a solid foundation for subsequent real-time drive, monitoring, analysis, and optimization, and effectively improving the accuracy and reliability of the virtual-real mapping.

[0010] As a preferred embodiment of the present invention, in step S3, constructing the 3D digital twin workshop includes mathematically describing the three-dimensional scene model of the packaging workshop, and the three-dimensional scene model of the packaging workshop is composed of a combination of a feeding and material separation unit, a packaging film conveying unit, a pre-packaging and heat shrinkage unit, a workshop film cutting unit, and a workshop control unit.

[0011] To implement the above technical solution, by mathematically describing the three-dimensional scene model of the packaging workshop, it is clear that the model is composed of multiple independent and interrelated combined units such as a feeding and material separation unit, a packaging film conveying unit, a pre-packaging and heat shrinkage unit, a workshop film cutting unit, and a workshop control unit. This composition method reflects the modular and hierarchical modeling idea of the complex physical workshop structure. Through this precise and structured mathematical description, the present invention can accurately construct a high-fidelity 3D digital twin model corresponding to the real packaging workshop, providing an accurate spatial basis for virtual-real mapping. This modular combined modeling method not only improves the construction efficiency and maintainability of the model, but also provides a clear geometric reference for subsequent component-level motion simulation and overall motion control cooperation, thus ensuring the high precision of the digital twin system in reflecting the real layout and functions of the physical world.

[0012] As a preferred embodiment of the present invention, in step S4, analyzing the complex production behavior of the production equipment includes mathematically describing the geometric transformation of the translation and rotation behaviors of the equipment to realize the movement of the virtual model.

[0013] To implement the above technical solution, by mathematically describing the geometric transformation of the translation and rotation behaviors of the equipment, the present invention can accurately control the movement trajectory and posture of the virtual model in the digital twin environment, realizing a high degree of consistency in the movement behavior between the virtual model and the physical equipment. This not only ensures the high precision and realism of the digital twin system simulation, but also provides a reliable motion data basis for subsequent virtual-real linkage, fault diagnosis, and production optimization, thus improving the precise control ability and simulation effect of the entire monitoring system.

[0014] As a preferred embodiment of the present invention, the preprocessing of the collected data includes: Encapsulating the collected multi-source heterogeneous data into data of a unified format; Filtering the data after the format is unified, and eliminating redundant data irrelevant to scene mapping; Classifying and summarizing the collected motion data as needed.

[0015] Implementing the above technical solution ensures that the data input into the digital twin system has high availability, high accuracy, and high relevance. The unified format solves the compatibility problems brought by multi-source heterogeneous data; the elimination of redundant data effectively reduces the data processing burden and transmission pressure of the system, avoiding unnecessary consumption of computing resources; and the classification and induction of motion data make the data more structured and manageable, providing a high-quality and refined data foundation for subsequent virtual entity motion control and visualization. This jointly improves the data processing efficiency and overall performance of the digital twin system, ensuring the accuracy and real-time nature of the virtual-real mapping.

[0016] As a preferred solution of the present invention, in step S1, the preprocessed data is transmitted in real time based on network communication, which specifically includes: Create an OPC UA server port and bind the IP and port number of the client; Monitor the client IP and port and wait for the remote connection of the client; Create an OPC UA client and subscribe to connect to the server; After the connection between the OPC UA client and the server is completed, the server sends the preprocessed data to the client, and the client receives the data; after the client receives the data input, it outputs two data streams. One data stream flows into the database for storage, and the other data stream flows into Unity3D; Perform historical data analysis on the data passed into the database to achieve fault prediction; Drive the workshop monitoring system through the data passed into Unity3D.

[0017] Implementing the above technical solution, first create an OPC UA server port and bind the IP and port number of the client, and then monitor the client connection; on the other end, create an OPC UA client and actively subscribe to connect to the server. Once the connection between the client and the server is completed, the server sends the preprocessed data to the client in real time. After receiving the data, the client splits the data stream into two parallel data streams. One data stream flows into the database for permanent storage, and the other data stream flows into the Unity3D simulation environment. By constructing a reliable communication link based on OPC UA, the present invention realizes the efficient, stable, and real-time transmission of production data in the physical world to the digital twin system, ensuring the synchronization of the virtual-real mapping. The data splitting mechanism effectively applies the data to different purposes: the data passed into the database supports the in-depth analysis of historical data and fault prediction, improving the early warning and diagnosis capabilities of the system; while the data passed into Unity3D directly drives the digital twin workshop monitoring system, realizing the high-precision linkage and visual presentation of the virtual model and the behavior of real devices. This significantly enhances the data utilization efficiency, real-time monitoring ability, and intelligent operation and maintenance level of the digital twin system.

[0018] As a preferred solution of the present invention, the real-time driving method of the digital twin workshop includes: Dividing the real-time transmitted motion data into frames according to a time interval; Calling the motion script frame by frame, and using a loop to call the motion control function in the motion script once per frame for driving.

[0019] To implement the above technical solution, first divide the real-time transmitted motion data into frames according to a preset time interval. Subsequently, the system calls the pre-written motion script frame by frame, and uses a loop mechanism to ensure that the motion control function in the motion script can be called once per frame, so as to achieve precise driving of the virtual model. Through this driving mechanism based on frame division and loop call, the present invention ensures that the motion of the virtual digital twin workshop is highly synchronized and real-time with the operation of the physical world equipment. This driving method can accurately restore the dynamic behavior of physical equipment, enabling the digital twin system to timely reflect the real state changes in the production site, providing accurate and real-time monitoring views and simulation experiences for operators, and thus improving the response speed and decision-making efficiency of the entire digital twin monitoring system.

[0020] As a preferred solution of the present invention, the product information includes product model, product technical parameters, and product specifications; the material information includes bill of materials, production quantity information, and consumption quantity; the production equipment information includes production equipment model, production technical parameters, and equipment performance information; the environmental information includes the temperature, humidity, and noise in the production workshop; the equipment status information includes motion data.

[0021] To implement the above technical solution, the specific composition of various production data is further clarified. Its movement process lies in refining the production data to be collected and transmitted into multiple dimensions, including: product information, covering product model, product technical parameters, and product specifications; material information, including bill of materials, production quantity information, and consumption quantity; production equipment information, involving production equipment model, production technical parameters, and equipment performance information; environmental information, specifically referring to the temperature, humidity, and noise in the production workshop; and equipment status information, specifically referring to motion data. The clear definition and classification of these information ensure the comprehensiveness and pertinence of data collection. By classifying and defining various production data so meticulously and comprehensively, the present invention can ensure that the data obtained by the digital twin system has rich dimensions and high relevance. This provides a comprehensive and accurate data basis for the precise modeling, real-time motion control, visual presentation, and subsequent fault prediction and production optimization of virtual entities in the digital twin environment. By collecting and utilizing these detailed information, the system can more truly and completely reflect the actual operation status of the physical workshop, thereby significantly improving the operation accuracy, analysis depth, and management intelligence level of the digital twin system.

[0022] The present invention also discloses a monitoring system for a digital twin packaging workshop, including: A data module, configured to collect various production data during the general assembly process of the digital twin workshop through a communication protocol, preprocess the collected data, and perform real-time transmission of the preprocessed data based on network communication to provide motion data during the general assembly process of the virtual entity; the various production data includes product information, material information, and production equipment information determined before production starts, as well as equipment status information and product information generated during the production process; A modeling module, configured to build a behavior model based on Petri nets, and the behavior model can reflect the logical relationships of triggering the packaging equipment to start working when materials arrive in the packaging workshop, entering the next link after the previous packaging link is completed, and the change of material status guiding the process into a new stage; A motion module, configured to analyze the complex production behaviors of the production equipment used in the general assembly process of the digital twin workshop, decompose the motion actions of each equipment component one by one according to the relationships between the production equipment, and perform overall motion control coordination to complete the motion of the entire equipment; A driving module, configured to perform simulation mapping based on the behavior logic model, real-time transmitted data, and the decomposition of the complex production behaviors of the production equipment to achieve real-time driving of the digital twin workshop.

[0023] To implement the above technical solution, the data module first collects and preprocesses various production data during the general assembly process of the digital twin workshop through a communication protocol, and performs real-time transmission based on network communication to provide data support for the motion of the virtual entity; the modeling module is responsible for building a behavior model based on Petri nets, and this model can accurately reflect the logical relationships of material arrival, link transfer, and status change in the production process of the packaging workshop; the motion module analyzes the complex behaviors of the production equipment, decomposes the motion actions of each component and coordinates the overall motion control to accurately control the motion of the virtual equipment; finally, the driving module performs simulation mapping based on the behavior logic model, real-time transmitted data, and the decomposition of the complex behaviors to achieve real-time driving of the digital twin workshop. Through the collaborative work of each module, a comprehensive, real-time, and high-precision virtual-real mapping and monitoring of the general assembly process of the physical packaging workshop are realized. Its technical effect is that it can significantly improve the visualization degree, monitoring efficiency, and prediction accuracy of the production process in the packaging workshop. Through data-driven simulation, it provides real-time decision support for production management, helps to achieve transparent, intelligent operation, and efficient operation and maintenance management of the production site. Brief Description of the Drawings

[0024] Figure 1 It is a flow logic diagram of the method according to the embodiment of the present invention.

[0025] Figure 2Schematic diagram of a Petri net model according to an embodiment of the present invention.

[0026] Figure 3 To implement the digital twin model monitoring system environment for the present invention.

[0027] Figure 4 The digital twin model monitoring interface is displayed for the implementation of the present invention. DETAILED DESCRIPTION

[0028] The specific implementation modes of the present invention are further described below in conjunction with the accompanying drawings to make the technical solutions of the present invention easier to understand and grasp.

[0029] See also Figure 1 Embodiment 1: A virtual-real mapping method for an assembly process of a digital twin workshop, comprising: S1: Based on the industrial communication protocol OPC UA, various types of production data in the assembly process of the digital twin packaging workshop are collected, the collected data are encapsulated into a unified format and then a preprocessing step of multi-source data classification is performed. The preprocessed data is transmitted in real time based on network communication to provide motion data that drives the motion control of virtual entities, as well as multi-source data for visual large-screen charts.

[0030] Various types of production data include environmental information, material information and production equipment information determined before production, as well as equipment status information generated during the production process. Among them, environmental information includes workshop temperature, workshop noise, and workshop humidity; material information includes bill of materials, production quantity information, and consumables; production equipment information includes production equipment model, production technical parameters, and equipment performance information; equipment status information includes motion data, speed, angle, and position of production robot arms.

[0031] Among them, the collected data is preprocessed, including: encapsulating the collected multi-source heterogeneous data into data in a unified format; filtering the data after the unified format to eliminate redundant data irrelevant to the scene mapping; and classifying and summarizing the collected motion data as needed.

[0032] Real-time transmission of pre-processed data, including: Create an OPC UA server port and bind the client's IP and port number; The OPC UA server listens to the client and waits for the client to connect; Create an OPC UA client, subscribe to the server, and then connect; After the OPC UA client and server complete the connection, the server sends the pre-processed data to the client, and the client receives the data; After the client accepts data input, it outputs in two data streams and passes them into the database and Unity3D respectively; Passing into the database enables permanent storage of data, facilitating background analysis of historical data for fault prediction; Passing into Unity3D can implement a data-driven workshop monitoring system.

[0033] Step S2: Analyze the production status and production behavior of the general assembly work process in the digital twin workshop, and construct a behavior model based on Petri nets according to the mapping rules. The key lies in clarifying the process components of the model and their logical relationships with each other. These process components include two categories: places and transitions. Places represent the status of the packaging workshop at a specific time point, and this status will affect the subsequent production and processing processes. The behavior logic model of Petri nets is used to describe the movement rules during the general assembly process of virtual entities.

[0034] To more accurately describe the characteristics and operations of each stage, the object-oriented modeling idea is introduced, and models are constructed for each stage one by one. This logical Petri net model draws on the specific structural layout of the packaging workshop and analyzes the processing logic and technological process of the workshop.

[0035] As Figure 2 shown, in the packaging process, five key production nodes are represented by 1 to 5. These nodes are closely related to places S and P, and the latter two reflect the real-time operating status of each mechanical equipment on the production line. This representation method helps to comprehensively understand and monitor the operating status of the packaging workshop. During the production process, S1 - S5 represent the preparation action status of each system of the packaging machine. S1 represents the preparation for material feeding and distribution, and S5 represents the preparation for the film cutting system to cut the film; P1 - P5 represent the action completion status of each system of the packaging machine respectively. Among them, P1 specifically refers to the completion status of the action of material feeding and distribution, and P5 specifically refers to the completion status of film cutting. The set of transitions T represents various operations that cause corresponding changes to the parts to be processed during the production process. T1 - T5 represent the transitions when the parts to be processed enter different packaging nodes, and T6 - T9 represent the transitions of the buffer conveyor belts at the production nodes, which are responsible for transporting the processed parts in the previous node to the next production node.

[0036]

[0037] Combine the Petri net with the digital twin model. The digital twin model includes physical entities, virtual entities, data, services, and connections, where: Physical entities include workshop equipment such as packaging machines, conveyor belts, and production materials; virtual entities are virtual models constructed based on physical entities through computer modeling and simulation technologies, facilitating the restoration of the workshop; data includes data information read and stored from devices such as sensors and PLCs of physical entities using the OPC UA communication protocol, and also includes simulation data obtained by the digital twin through process simulation, behavior simulation, process verification, fault detection, and behavior prediction.

[0038] The service dimension refers to providing various value-added services to users or systems through the digital twin model. These services can be intelligent decision support, predictive maintenance, optimized scheduling, risk assessment, aiming to improve efficiency, reduce costs, and enhance the user experience.

[0039] The connection dimension refers to ensuring stable data transmission throughout the digital twin system through Internet of Things technologies, mainly including standard protocols such as MQTT, OPC UA, and Modbus.

[0040] The behavior logic based on Petri nets constructed in this application more precisely describes the characteristics and operations of each stage, introduces the object-oriented modeling concept, and constructs models for each stage one by one. By analyzing the workshop processing logic and technological processes, it can provide a dynamic and accurate mapping of the assembly production line site for the digital twin monitoring system.

[0041] The dynamic process of the simulated production workshop includes: when the production line in the packaging workshop starts running, material preparation for feeding and splitting (S1), when the material and splitting are completed (P1), the process T1 of the material sensing and entering the packaging area can proceed, and finally enter the buffer conveyor belt T7, and then proceed to the next packaging unit until the packaging is completed. Based on the logical Petri net model constructed for the packaging workshop, it comprehensively covers the production behavior logic and corresponding technological processes, providing a basis for the virtual-real mapping between the physical workshop and the twin packaging workshop.

[0042] Step S3: Construct a 3D digital twin workshop corresponding to the real workshop. The specific process of the packaging machine model in the 3D digital twin workshop corresponding to the batch of packaging machines is as follows: According to the design original drawings of the packaging machine, use SolidWorks modeling software to perform non-material modeling on the feeding and splitting unit, packaging film conveying unit, pre-packaging and heat shrinking unit, film cutting unit, and control unit of the packaging machine to obtain a non-material packaging machine model.

[0043] Mathematically describe the three-dimensional modeling of production equipment:

[0044] Among them: Represents the three-dimensional scene model of the packaging workshop; Represents the feeding and material distribution unit; Represents the packaging film conveying unit; Represents the pre-packaging and heat shrinkage unit in the packaging workshop; Represents the film cutting unit in the workshop; Represents the workshop control unit; n, o, p, q, r, m respectively represent all the model quantities under each packaging unit.

[0045] In the Unity3D animation engine, the virtual roaming and movement of models rely on geometric transformations. Therefore, a mathematical description is given to the translation and rotation behaviors used in production equipment.

[0046] To achieve the displacement transformation of the virtual model, a 4*4 homogeneous transformation matrix is adopted. Similarly, the transformation matrix in Unity3D is also of the 4*4 specification, which is also to meet the needs of non-linear transformations such as displacement transformation.

[0047] Displacement transformation: Where: Respectively represent the distances moved on x, y, and z.

[0048] In the Unity3D environment, the transformation matrix representing rotation around the x-axis has a specific form, specifically:

[0049] In the Unity3D environment, the transformation matrix representing rotation around the y-axis has a specific form, specifically:

[0050] Step S4: Analyze the complex production behaviors of the production equipment in the digital twin workshop. According to the relationships between the production equipment, decompose the motion actions of each equipment component one by one, and then carry out the overall motion control coordination to complete the driving of the entire equipment.

[0051] After the construction of the behavior logic model based on Petri nets and the completion of complex motion decomposition, it is necessary to call the preprocessed data to perform the overall motion mapping. In order to finally achieve real-time data-driven of the model, it needs to solve two problems: the model motion mapping method and data update call.

[0052] This simulation is completed through the Unity3D physics engine, and the motion is realized by calling scripts; In Unity3D, the Transform component is the key to controlling the transformation of three-dimensional virtual models. It covers three major attributes: displacement (Position), scaling (Scale), and rotation (Rotation). By binding the corresponding parent-child relationships and attaching the edited scripts, the dynamic effects of the model motion components can be achieved.

[0053] Among them, the displacement transformation of the model can be achieved by calling the Transform.Position property or the Transform.Translate function. The scaling transformation is controlled by using the Transform.Scale property or related functions. As for the rotation transformation, Unity3D provides two ways to achieve it: Transform.Rotate() and Transform.Rotation.

[0054] Among them, the transform.Rotate function allows the user to rotate an Euler angle in the order of the x, y, and z axes, and it can perform cumulative rotation on the basis of the original angle. The Transform.Rotation property represents the rotation using quaternions. By being called frame by frame through the Update function of Unity3D, the angle rotation of the model can be achieved, and the gimbal lock problem that may occur during Euler angle rotation can be effectively avoided.

[0055] For the implementation of real-time transmitted data and model motion mapping, the main methods include: calling API interfaces or coroutine class methods in Unity; Adding physical effects, adding gravity, mass, performing collision detection to prevent the models from penetrating each other, and then coordinating the movements between devices.

[0056] Step S5: Based on the above behavior logic model, real-time data transmission, and the decomposition of the complex production behavior of the production equipment, conduct a simulation experiment in the Unity3D engine to initially complete the real-time drive and monitoring of the digital twin workshop.

[0057] Embodiment 2: A monitoring system for a digital twin packaging workshop, including the virtual-real mapping method for the general assembly process of a digital twin workshop in Embodiment 1, further including: A data module, used to collect various production data during the general assembly process of the digital twin workshop through a communication protocol, preprocess the collected data, and perform real-time transmission of the preprocessed data based on network communication to provide motion data during the general assembly process of the virtual entity; the various production data includes product information, material information, and production equipment information determined before the start of production, as well as equipment status information and product information generated during the production process; A modeling module, used to build a behavior model based on Petri nets, and the behavior model can reflect the logical relationships of triggering the packaging equipment to start working when materials arrive in the packaging workshop, entering the next link after the completion of the previous packaging link, and the change of material status guiding the process into a new stage; The motion module is used to analyze the complex production behaviors of the production equipment used in the general assembly process of the digital twin workshop. According to the relationships between the production equipment, the motion actions of each equipment component are decomposed one by one, and overall motion control cooperation is carried out to complete the motion of the entire equipment. The driving module is used to perform simulation mapping based on the behavior logic model, real-time transmitted data, and the decomposition of the complex production behaviors of the production equipment, so as to realize the real-time driving of the digital twin workshop.

[0058] Of course, the above are only typical examples of the present invention. In addition, the present invention can also have many other specific implementation manners. Any technical solutions formed by equivalent replacement or equivalent transformation fall within the scope of protection required by the present invention.

Claims

1. A virtual-real mapping method for the general assembly process of a digital twin workshop, characterized in that It includes the following steps: S1: Collect various production data during the general assembly process in the packaging workshop based on the industrial communication protocol OPC UA, encapsulate the collected data in a unified format and perform multi-source data classification and preprocessing, and transmit the preprocessed data in real time through network communication to provide the motion data required for virtual entity motion control and the multi-source data required for visualization; the various production data includes the environmental information, material information, production equipment information determined before production, and the equipment status information generated during the production process; S2: Analyze the production status and production behavior of the overall work process in the packaging workshop, and construct a behavior logic model based on Petri nets according to the mapping rules to describe the motion rules during the general assembly process of the virtual entity; S3: Construct a 3D digital twin workshop corresponding to the real workshop, where the packaging machine model in the 3D digital twin workshop is lightweight processed; S4: Analyze the complex production behavior of the production equipment in the digital twin workshop, decompose the motion actions of each equipment component according to the relationship between the production equipment, and perform overall motion control cooperation to complete the drive of the equipment; S5: Based on the behavior logic model, real-time transmitted data, and the decomposition of the complex production behavior of the production equipment, conduct simulation experiments in the Unity3D engine to achieve real-time drive and monitoring of the digital twin workshop.

2. The virtual-real mapping method for the general assembly process of a digital twin workshop according to claim 1, wherein The specific content of step S2 includes: According to the production status and production behavior of the overall work process in the packaging workshop, abstract the production status as the places of the Petri net, and abstract the production behavior as the transitions of the Petri net; the places include the places representing the preparation action status of each system of the packaging machine and the places representing the action completion status of each system of the packaging machine; the transitions include the transitions when the parts to be processed enter different packaging nodes and the transitions representing the buffer conveyor belts of the production nodes.

3. A virtual-real mapping method for the general assembly process of a digital twin workshop according to claim 1, characterized in that, In step S3, constructing the 3D digital twin workshop includes mathematically describing the three-dimensional scene model of the packaging workshop, and the three-dimensional scene model of the packaging workshop is composed of a combination of a feeding and material separation unit, a packaging film conveying unit, a pre-packaging and heat shrinkage unit, a workshop film cutting unit, and a workshop control unit.

4. A virtual-real mapping method for the general assembly process of a digital twin workshop according to claim 1, characterized in that, In step S4, analyzing the complex production behavior of the production equipment includes mathematically describing the geometric transformation of the translation and rotation behaviors of the equipment to realize the motion of the virtual model.

5. A virtual-real mapping method for the general assembly process of a digital twin workshop according to claim 1, characterized in that, The preprocessing of the collected data includes: Encapsulating the collected multi-source heterogeneous data into data in a unified format; Filtering the data after the format is unified, and eliminating redundant data irrelevant to the scene mapping; Classifying and summarizing the collected motion data as needed.

6. The virtual-real mapping method for the general assembly process of a digital twin workshop according to claim 1, characterized in that In step S1, the real-time transmission of the preprocessed data based on network communication specifically includes: Create the server port of OPC UA and bind the IP and port number of the client; Monitor the client IP and port and wait for the remote connection of the client; Create an OPC UA client and subscribe to connect to the server; After the connection between the OPC UA client and the server is completed, the server sends the pre-processed data to the client, and the client receives the data; after receiving the data input, the client outputs it in two data streams, one of which flows into the database for storage, and the other data stream flows into Unity3D; Historical data analysis is performed on the data passed into the database to achieve fault prediction; The workshop monitoring system is driven by the data passed into Unity3D.

7. A virtual-reality mapping method for the general assembly process of a digital twin workshop according to claim 1, characterized in that, The real-time driving method of the digital twin workshop includes: Dividing the real-time transmitted motion data into frames according to time intervals; Calling the motion script frame by frame, and using a loop to call the motion control function in the motion script once per frame for driving.

8. A virtual-real mapping method for the general assembly process of a digital twin workshop according to claim 1, characterized in that: The product information includes product model, product technical parameters, and product specifications; the material information includes bill of materials, production quantity information, and consumable quantity; the production equipment information includes production equipment model, production technical parameters, and equipment performance information; the environmental information includes temperature, humidity, and noise in the production workshop; the equipment status information includes motion data.

9. A monitoring system for a digital twin packaging workshop, characterized in that, It includes a virtual-real mapping method for the general assembly process of a digital twin workshop according to any one of claims 1-8, and further includes: A data module for collecting various production data in the general assembly process of the digital twin workshop through a communication protocol, pre-processing the collected data, and performing real-time transmission of the pre-processed data based on network communication to provide motion data in the virtual entity general assembly process; the various production data includes product information, material information, and production equipment information determined before production starts, as well as equipment status information and product information generated during production; A modeling module for constructing a behavior model based on Petri nets, which can reflect the logical relationships of triggering the packaging equipment to start working when materials arrive in the packaging workshop, entering the next link after the previous packaging link is completed, and the change of material status guiding the process into a new stage; A motion module for analyzing the complex production behaviors of the production equipment used in the general assembly process of the digital twin workshop, decomposing the motion actions of each equipment component one by one according to the relationships between the production equipment, and performing overall motion control cooperation to complete the motion of the entire equipment; A driving module for performing simulation mapping based on the behavior logic model, real-time transmitted data, and the decomposition of the complex production behaviors of the production equipment to achieve real-time driving of the digital twin workshop.

Images