Transmission line digital twinning virtual debugging system and method based on B / S (Browser / Server) architecture

Abstract

The invention relates to the technical field of PLC control, in particular to a B / S architecture-based digital twin virtual debugging system and method for a transmission line. The system comprises a three-layer B / S (Browser / Server) architecture consisting of a PLC (Programmable Logic Controller) simulation layer, a business logic layer and a three-dimensional visualization layer, the PLC simulation layer is used for operating a PLC program to obtain a feedback signal of the controlled equipment, simulating the control logic of the PLC to the controlled equipment based on the feedback signal, and sending a control signal to the service logic layer; the business logic layer is used for acquiring the control signal and carrying out business logic operation based on the control signal and the feedback signal so as to calculate and simulate the movement of the controlled equipment and obtain real-time position data; and the three-dimensional visualization layer is used for displaying the operation state of the controlled equipment based on a pre-constructed virtual model of the controlled equipment and the real-time position data so as to display the operation result of the PLC program, generating a feedback signal based on a virtual sensor on the virtual model of the controlled equipment, and sending the feedback signal to the business logic layer.

Description

Technical Field

[0001] The present application relates to the field of PLC control technology, and in particular to a conveyor line digital twin virtual debugging system and method based on a B / S architecture. Background Art

[0002] As smart manufacturing upgrades, the demand for more flexible production lines in the discrete manufacturing industry places higher demands on equipment debugging efficiency. Traditional physical debugging methods rely on on-site joint debugging of mechanical, electrical, and control systems, which presents numerous drawbacks, including long debugging cycles, high trial-and-error costs, and difficulties in cross-regional collaboration. Especially in complex conveyor line scenarios, PLC program logic verification requires repeated startup and shutdown of real equipment. This not only increases mechanical wear but can also lead to delayed sensor signal feedback or incorrect control instructions written by debuggers due to programming oversight or poor logic design, causing cascading failures, mechanical damage, and even casualties.

[0003] In recent years, to address the aforementioned challenges of physical debugging, a number of virtual debugging software based on a client / server architecture (e.g., Unity) have emerged on the market. However, while these solutions address existing issues, they also introduce new technical bottlenecks. First, virtual debugging client software based on a client / server architecture is typically bulky and requires high local computer hardware configuration, resulting in a high barrier to deployment and use. Second, software licensing fees are expensive and deeply tied to specific operating systems or platforms, resulting in limited flexibility (e.g., poor compatibility with domestic platforms such as Kylin).

[0004] In summary, traditional debugging methods and existing technologies have obvious shortcomings in meeting the needs of modern intelligent manufacturing, and it is difficult to debug and optimize controlled equipment efficiently, accurately and at low cost. Summary of the Invention

[0005] In view of this, the embodiments of the present application are committed to providing a conveyor line digital twin virtual debugging system and method based on B / S architecture.

[0006] This application provides a conveyor line digital twin virtual debugging method based on B / S architecture, including a three-layer B / S architecture consisting of a PLC simulation layer, a business logic layer, and a three-dimensional visualization layer; PLC simulation layer: used to run the PLC program and simulate the PLC program, obtain the feedback signal of the controlled device, simulate the control logic of the PLC on the controlled device based on the feedback signal, and send the control signal to the business logic layer; A business logic layer, in communication with the PLC simulation layer, is configured to obtain the control signal and perform business logic operations based on the control signal and the feedback signal to calculate the motion of the simulated controlled device and obtain real-time position data; Three-dimensional visualization layer: Communicating with the business logic layer, it is used to display the operating status of the controlled device based on the pre-built virtual model of the controlled device and the real-time position data to show the operating results of the PLC program, and generate feedback signals based on the virtual sensors on the virtual model of the controlled device and send them to the business logic layer.

[0007] In some embodiments, the PLC simulation layer includes: PLC programming submodule: used to write the PLC program; PLC simulation submodule: used to simulate the PLC program to simulate the control logic of the PLC on the controlled device.

[0008] In some embodiments, the business logic layer includes: Signal processing submodule: used for processing the control signal generated by the PLC program simulation and the feedback signal from the controlled device; Business logic operation submodule: used to perform business logic operation according to the signal processed by the signal processing submodule; Configuration management submodule: used to manage the configuration information of the controlled device and generate the corresponding controlled device according to the configuration information; Kinematics calculation submodule: used to calculate the motion state of the controlled device according to the calculation results of the business logic calculation submodule and the dynamic model of the controlled device to obtain real-time position data.

[0009] In some embodiments, the three-dimensional visualization layer includes: Scenario construction submodule: used to build a virtual model of the controlled device; Model loading and updating submodule: used to load the virtual model of the controlled device in the virtual scene and update the operating status of the virtual model according to the real-time location data of the business logic layer; The sensor simulation submodule is used to simulate the detection logic of the sensor in the virtual scene and generate a corresponding sensor signal; wherein the sensor signal is a feedback signal.

[0010] In some embodiments, the business logic layer and the three-dimensional visualization layer communicate using the WebSocket protocol to achieve real-time data transmission; Redis message queue is used between the PLC simulation layer and the business logic layer to achieve asynchronous decoupling of signals and data.

[0011] In some embodiments, the three-dimensional visualization layer is further used to: obtain data information obtained by running the PLC program on a physical device of the controlled device; and adjust the virtual model of the controlled device based on the data information.

[0012] The present application provides a conveyor line digital twin virtual debugging method based on B / S architecture. The method comprises the following steps: Deploy the PLC simulation layer, business logic layer, and 3D visualization layer on the server side; A PLC program is written through the PLC programming submodule, and is used to run the PLC program in the PLC simulation layer, and the PLC program is simulated to obtain feedback signals from the controlled devices. Based on the feedback signals, the PLC control logic for the controlled devices is simulated and control signals are sent to the business logic layer. The control signal generated by the PLC program simulation is received through the business logic layer, and the signal asynchronous transmission and decoupling between the PLC simulation layer, the business logic layer and the three-dimensional visualization layer are realized through the preset message middleware; updating the operating status of the virtual model of the controlled device according to the calculation results of the business logic layer through the three-dimensional visualization layer and displaying it in the client browser; The detection logic of the sensor is simulated in the virtual scene, and the corresponding sensor signal is generated and fed back to the PLC simulation layer through the message middleware, forming a closed-loop signal feedback link, and realizing two-way interaction between the virtual model and the PLC program.

[0013] In some embodiments, the business logic layer implements asynchronous transmission and decoupling of signals between the PLC simulation layer, the business logic layer, and the three-dimensional visualization layer through the following steps: The business logic layer converts the control signal generated by the PLC program simulation into a message in a preset format and sends it to the message middleware; The message middleware caches the message and forwards the message to a corresponding target module according to a preset routing rule; wherein the target module includes at least one of a PLC simulation layer and a business logic layer; The target module receives the message from the message middleware and performs corresponding processing.

[0014] In some embodiments, further comprising: Obtaining data information obtained by running the PLC program on the physical device of the controlled device; The virtual model of the controlled device is adjusted based on the data information.

[0015] The present application provides an electronic device, including: A processor, and a memory for storing a program executable by the processor; The processor is used to implement the above-mentioned conveyor line digital twin virtual debugging method based on B / S architecture by running the program in the memory.

[0016] The present application provides a conveyor line digital twin virtual debugging system based on B / S architecture, including a three-layer B / S architecture consisting of a PLC simulation layer, a business logic layer, and a three-dimensional visualization layer; The PLC simulation layer is used to run and simulate the PLC program, obtain feedback signals from the controlled devices, simulate the PLC control logic for the controlled devices based on the feedback signals, and send control signals to the business logic layer. The business logic layer is connected to the PLC simulation layer and is used to obtain the control signals and perform business logic operations based on the control signals and the feedback signals to calculate and simulate the movement of the controlled devices to obtain real-time position data. The three-dimensional visualization layer is connected to the business logic layer and is used to display the operating status of the controlled devices based on pre-built virtual models of the controlled devices and the real-time position data to demonstrate the results of the PLC program. The virtual sensors on the virtual models of the controlled devices are used to generate feedback signals and send them to the business logic layer. With this configuration, the solution provided by this application provides a safe and low-cost virtual environment for running and simulating PLC programs, enabling engineers to perform logic verification and debugging of PLC programs without relying on actual physical devices. By receiving feedback signals and simulating the PLC's control logic for controlled devices, potential PLC program issues can be quickly identified and resolved in a virtual environment, reducing equipment downtime and production losses caused by program errors in real production environments. Compatibility and functionality issues between the PLC program and the controlled device can be identified before actual equipment installation and commissioning. This helps optimize program logic, ensuring the stability and reliability of the PLC program in actual operation and reducing project implementation risks. By optimizing the PLC program based on feedback signals, the accuracy and efficiency of the control logic can be improved. This not only improves the performance of the controlled equipment but also enables more complex control strategies, enhancing the automation and intelligence of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and other purposes, features, and advantages of the present application will become more apparent through a more detailed description of the embodiments of the present application in conjunction with the accompanying drawings. The accompanying drawings are intended to provide a further understanding of the embodiments of the present application and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation of the present application. In the drawings, the same reference numerals generally represent the same components or steps.

[0018] Figure 1This is a schematic diagram of a conveyor line digital twin virtual debugging system based on B / S architecture provided in one embodiment of the present application.

[0019] Figure 2 This is a schematic diagram of the flow of signals in a closed-loop feedback mechanism provided by an embodiment of the present application.

[0020] Figure 3 This is an embodiment of the present application that provides a technical route for data interaction and business processing layer (backend).

[0021] Figure 4 This is a flow chart of a conveyor line digital twin virtual debugging method based on B / S architecture provided in an embodiment of the present application.

[0022] Figure 5 This is a schematic diagram of the structure of an electronic device provided by an embodiment of the present application. DETAILED DESCRIPTION

[0023] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0024] As smart manufacturing upgrades, the demand for more flexible production lines in the discrete manufacturing industry places higher demands on equipment debugging efficiency. Traditional physical debugging methods rely on on-site joint debugging of mechanical, electrical, and control systems, which present industry challenges such as long debugging cycles, high trial-and-error costs, and difficulties in cross-regional collaboration. Especially in complex conveyor line scenarios, PLC program logic verification requires repeated startup and shutdown of real equipment, which not only increases mechanical wear but also potentially triggers cascading failures due to delayed sensor signal feedback.

[0025] In recent years, the browser / server (B / S) architecture has become increasingly popular in the manufacturing industry, with WebGL technology enabling high-precision 3D rendering on the browser side. However, existing B / S-based digital twin systems still face core challenges, including a lack of real-time signal loops, inefficient dynamic mapping of virtual and real devices, and insufficient sensor simulation accuracy. These challenges make it difficult to achieve the millisecond-level real-time interaction and high-fidelity virtual-real synchronization required for conveyor line debugging.

[0026] To address the aforementioned technical bottlenecks, the present invention proposes a conveyor line digital twin virtual debugging system based on a B / S architecture. This system utilizes a layered decoupling design of the PLC simulation layer, business logic layer, and 3D visualization layer, combined with Redis message middleware to achieve cross-layer asynchronous transmission of control signals and device status. A closed-loop feedback mechanism of "virtual device action → front-end sensor trigger → PLC response → model update" is constructed to support modular simulation of industrial sensors such as photoelectric / proximity switches. Dynamic device instantiation generation technology is developed to automatically map Three.js 3D configuration parameters to SpringBoot back-end device objects. Based on existing device models, this system and debugging method can significantly reduce debugging's reliance on physical devices, providing a lightweight, highly real-time virtual debugging infrastructure for intelligent manufacturing.

[0027] After introducing the basic principles of the present application, various non-limiting embodiments of the present application will be described in detail with reference to the accompanying drawings.

[0028] Reference Figure 1 、 Figure 2 , this application provides a conveyor line digital twin virtual debugging system based on B / S architecture, including a three-layer B / S architecture consisting of a PLC simulation layer, a business logic layer and a three-dimensional visualization layer; PLC simulation layer: used to run the PLC program and simulate the PLC program, obtain the feedback signal of the controlled device, simulate the control logic of the PLC on the controlled device based on the feedback signal, and send the control signal to the business logic layer; A business logic layer, in communication with the PLC simulation layer, is configured to obtain the control signal and perform business logic operations based on the control signal and the feedback signal to calculate the motion of the simulated controlled device and obtain real-time position data; Three-dimensional visualization layer: Communicating with the business logic layer, it is used to display the operating status of the controlled device based on the pre-built virtual model of the controlled device and the real-time position data to show the operating results of the PLC program, and generate feedback signals based on the virtual sensors on the virtual model of the controlled device and send them to the business logic layer.

[0029] Specifically, this system can be used for virtual debugging and optimization of PLC code for conveyor line systems in discrete manufacturing, logistics, and warehousing. Based on the virtual PLC and the virtual debugging system designed by this invention, PLC debuggers can accurately view the running results of the virtual PLC code in real time, making it easier for engineers to debug and optimize the PLC code.

[0030] The system designed in the present invention mainly includes three parts: a PLC simulation layer (PLC control and simulation part, which can be based on Siemens Botu and PLC Sim Advance), a business logic layer (data interaction and business processing part, i.e., the backend, which can preferably be developed using the SpringBoot framework of the Java language, or other technologies such as Django and Flask framework of the Python language, or the Node.js framework based on JavaScript, etc.), and a three-dimensional visualization layer (3D visualization part, i.e., the front end, which can be based on the Three.js framework).

[0031] Specifically, the PLC simulation layer includes: a PLC programming submodule: used to write the PLC program; a PLC simulation submodule: used to simulate the PLC program to simulate the control logic of the PLC on the controlled device.

[0032] Technology stack: Siemens Portu, PLC Sim Advance Use PLC Sim Advance software to simulate Siemens PLC (S1500 or S200, etc.). PLC debugging engineers can use Portu software to write PLC programs. This PLC program can be basically consistent with the PLC program in the actual site. This PLC program is burned into the PLC Sim Advance software, and with the help of the virtual debugging system designed in the application of this invention, the PLC program can be debugged and optimized according to the real-time operation effect of the equipment displayed in the 3D visualization part, realizing the virtual debugging and optimization function of the PLC program under the B / S architecture based on digital twins.

[0033] The business logic layer includes: a signal processing submodule: used to process the control signal generated by the PLC program simulation and the feedback signal from the controlled device; a business logic operation submodule: used to perform business logic operations based on the signal processed by the signal processing submodule; a configuration management submodule: used to manage the configuration information of the controlled device and generate the corresponding controlled device based on the configuration information; a kinematic calculation submodule: used to calculate the motion state of the controlled device based on the calculation results of the business logic operation submodule and the dynamic model of the controlled device to obtain real-time position data.

[0034] Technology stack: SpringBoot + Redis + JSON / XML configuration file + restful API + websocket protocol + snap7 protocol; Reference Figure 3 , the data interaction part is as follows: The front-end and back-end communicate using the WebSocket protocol for real-time data transmission. A Redis message queue is used between the back-end and the PLC simulation layer to achieve asynchronous decoupling of signals and data. Spring Boot uses the Snap7 protocol to directly read and write data from the database blocks of the Siemens S1500 virtual PLC.

[0035] Furthermore, other technologies such as Server-Sent Events (SSE) or HTTP long-polling can also be used to achieve similar functions in some scenarios.

[0036] The business processing part is specifically as follows: The business processing part is mainly divided into the following functional modules: front-end JSON configuration file parsing to generate virtual device class, PLC signal synchronization, cargo movement calculation in single-section equipment, cargo transfer and transportation in connected equipment, equipment sensor position calculation, websocket message push, inbound platform generation of cargo and outbound platform deletion of completed cargo functions.

[0037] Front-end JSON configuration file parsing to generate virtual device class function The system automatically maps YAML configurations using Spring Boot's property configuration annotations. The generated configuration file, generated after front-end scenario editing, is pushed to the server. The configuration file defines device instances, each associated with a pre-set type template. The device type template includes attributes such as the device ID, inlet and outlet topology, kinematic parameters (velocity / acceleration), and geometric path points (3D coordinates). The back-end automatically injects the device list in the YAML into a strongly typed collection using property configuration annotations. When the YAML configuration file changes, Spring's refresh scope annotation module, in conjunction with the file monitoring service, triggers a configuration reload.

[0038] PLC signal synchronization function Redis connection maintenance and abnormal recovery PLC signal data for relevant devices is deserialized from Redis at a fixed interval. Redis connection status is monitored by executing a scheduled task. When a query returns an exception, a reconnection operation is called. This mechanism ensures that even after network fluctuations or a Redis service restart, the system automatically restores the data channel after an initial delay of 5 seconds, providing a fundamental guarantee for PLC signal synchronization. Signal updates are atomically implemented, using atomic variables to store Boolean (AtomicBoolean), integer (AtomicInteger), and long integer (AtomicLong) signals to avoid variable conflicts when accessed by multiple threads. During initialization, atomic variables are pre-set based on the signal's enumeration class and can be directly manipulated to avoid concurrency conflicts when multiple threads update PLC data. PLC signal data for relevant devices is deserialized from Redis at a fixed interval and processed in three categories based on device type. Device instances are traversed to continuously update Boolean signals such as forward / reverse / high speed.

[0039] Cargo movement calculation function in single-section equipment Cargo Movement Calculation and Status Update Process: The system drives global cargo position updates through scheduled tasks, employing a hierarchical processing mechanism to perform differentiated calculations for different types of equipment. First, the system analyzes the equipment's operating status based on PLC control signals. The system uses a combination of forward and reverse signals to determine whether the equipment is stationary, moving forward, moving backward, or in an abnormal state, dynamically matching preset kinematic parameters (such as maximum speed and acceleration). For running equipment, a linear interpolation algorithm is used to calculate cargo displacement based on the path's starting and ending point coordinates, current progress, and acceleration function, updating the three-dimensional spatial coordinates and movement progress in real time.

[0040] Linear interpolation calculation: The displacement of the goods on the equipment path is calculated by normalizing the progress parameter (range [0,1]) to interpolate: in and are the three-dimensional coordinates of the starting point and end point of the path, Calculated from speed and time.

[0041] Acceleration integral model: When the device is in a uniform acceleration state, the instantaneous velocity and displacement increment The calculation is: in is the initial velocity, is the acceleration, is the time interval (defined by the time calculation interval).

[0042] Variable acceleration motion processing: If the acceleration changes with time (such as emergency stop or soft start and stop), use piecewise integration to calculate the displacement:

[0043] Numerical solution is achieved by discretizing the time step to ensure trajectory smoothness under complex working conditions.

[0044] Formula 1 is the interpolation logic, which generates a continuous trajectory through the coordinates of the path points; Formula 2-3 is the core algorithm, which supports constant or variable acceleration mode; Kinematic Model and Exception Handling Mechanism: The corresponding calculation model is selected based on the device's direction of travel. Forward motion uses a dynamic acceleration integration algorithm, combining time intervals to calculate instantaneous velocity and displacement. For reverse motion, the trajectory is inferred based on deceleration parameters. Path point integrity is verified in real time during the calculation process, and calculations are terminated and alarms are triggered for devices with abnormal configurations. During initialization, cargo positions are automatically located at the path starting point, and the initial pose is generated along the device's heading vector. A thread-safe data update strategy is implemented to ensure consistent positional states during concurrent calculations on multiple devices.

[0045] The cargo transfer system between connected devices monitors the readiness of adjacent devices in real time based on the device connection topology. Upon detecting that cargo has completed movement on the current device, a multi-stage verification process is initiated: first, the electrical interlocking logic between the current device's release signal and the target device's reception signal is verified; second, mechanical compatibility is checked (e.g., transfer machine lift position and roller conveyor operating direction); and finally, a capacity check ensures that the target device can handle the cargo. If any of these conditions are not met, the transfer is suspended and the status log is recorded.

[0046] Differentiated strategies for cargo transportation designed for different equipment combinations: Direct transfer between roller conveyors uses a coordinate mapping algorithm to move goods from the end of the current device to the starting point of the target device. This requires that the axes of the two devices are aligned and their speeds are matched. Roller conveyor-transfer machine collaboration requires simultaneous verification of the transfer machine's vertical positioning signals (UP / DN).

[0047] A double detection and rollback mechanism is introduced to ensure reliability: the device status is locked during the transfer process to avoid concurrent modifications that may cause position confusion; if the transfer takes more than 500ms, the goods are automatically returned to the end of the source device and an alarm is triggered.

[0048] Device sensor position calculation function For each type of device, if there is a sensor on the device that needs to be moved (such as a proximity switch sensor on an elevator), the sensor's base installation position is defined in the configuration file. When the device moves, the sensor's global coordinates are dynamically updated based on the device's displacement (such as the elevator's lift height) and the rotation matrix.

[0049] WebSocket communication mechanism The system integrates WebSocket services based on SpringBoot to achieve full-duplex real-time communication between the browser and the backend: the server maintains a long connection session pool. After the front-end establishes a connection through the ws: / / protocol, it uses the Protobuf protocol to compress and transmit data packets. The message types are divided into two categories: the world coordinates of all goods (incremental update cycle 100ms) and the sensor position (incremental update cycle 100ms). The server supports multiple clients to concurrently subscribe to the same scenario through a message partition routing mechanism. In the event of an abnormal disconnection, the server suspends message sending and attempts to automatically reconnect. After reconnection, the latest status is synchronized. At the same time, built-in heartbeat detection and flow control strategies ensure communication stability and real-time performance in high-concurrency scenarios (end-to-end delay <200ms).

[0050] The three-dimensional visualization layer includes: a scene construction submodule: used to construct a virtual model of the controlled device; a model loading and updating submodule: used to load the virtual model of the controlled device in the virtual scene and update the operating status of the virtual model according to the real-time position data of the business logic layer; a sensor simulation submodule: used to simulate the detection logic of the sensor in the virtual scene and generate corresponding sensor signals; wherein the sensor signals are feedback signals.

[0051] (1) Construction of digital twin 3D scene based on Threejs: The Three.js engine was used to build high-precision industrial scenes, loading pre-built conveyor equipment and cargo models in GLTF / GLB format. Leveraging VUE3's responsive data binding, the motion of equipment in the scene (such as roller conveyor rotation and transfer machine translation) was dynamically controlled. Cargo coordinate data calculated by the backend was received in real time via WebSocket to drive the displacement animation of the virtual cargo model.

[0052] (2) Sensor modular simulation and batch communication configuration method The system adopts modular design to realize the creation and management of virtual sensors and dynamically calculates the spatial position of sensors based on device path points.

[0053] For virtual simulation of photoelectric sensors: Automatically create a vertical or parallel sensor array based on the equipment type (such as a roller conveyor or transfer machine), determine the installation position through path point coordinates and offset parameters (such as an end distance ratio of 0.1-0.15), and use ray detection technology to construct a three-dimensional collision detection area.

[0054] This application uses a sensor signal generation method based on front-end ray detection, rather than treating the entire device as a state machine model as in other simulation methods in the industry. Its technical advantage lies in its ability to accurately simulate the nonlinear motion process of the conveyor belt under complex working conditions such as speed change, emergency stop, and flexible start and stop, and to accurately simulate the specific time and trigger position of the photoelectric sensor when irregularly shaped goods move on the conveyor belt. This enables the system to expose and verify PLC program logic defects that are closely related to the shape of the goods, equipment acceleration and deceleration, and timing, which cannot be discovered by traditional simplified simulation models, greatly improving the fidelity and reliability of virtual debugging.

[0055] A JSON configuration file defines the sensor type (photoelectric / proximity switch) and sensor trigger distance. Sensors are topologically sorted according to the user-defined device order, and the actual number of sensors generated is verified to be consistent with the configuration. Anomalies trigger an alarm log to ensure that the detection sequence complies with the conveyor line control logic. When goods enter the X-ray detection range, sensor trigger parameters are dynamically updated.

[0056] During the communication between the websocket and the backend, the system reserves a number (for example, 10,000) Boolean value slots. By manually sorting the configured and generated virtual sensors of various Boolean types, the system can push the status of these sensors to the PLC simulation layer, achieving millisecond-level synchronization between physical signals and virtual detection.

[0057] (3) Configuration file generation The system provides the ability to generate multi-format configuration files, supports structured storage and flexible adaptation of equipment data, defines standardized interfaces based on equipment type (roller conveyors, transfer machines, elevators, etc.), encapsulates core attributes such as equipment ID, path points, and sensor parameters, and ensures data integrity through type verification functions.

[0058] Furthermore, the three-dimensional visualization layer is further used to: obtain data information obtained by running the PLC program on a physical device of the controlled device; and adjust the virtual model of the controlled device based on the data information.

[0059] Specifically, data acquisition: In a real-world production environment, controlled physical conveyor line equipment operates according to PLC programs, generating a series of data containing key information such as equipment operating status and production data. The 3D visualization layer has the ability to acquire data from these physical devices. This can be achieved through sensors, data acquisition systems, and other technical means, enabling the collection of real-time or near-real-time data from these physical devices.

[0060] Virtual Model Adjustment: After acquiring data from the physical device, the 3D visualization layer adjusts the virtual model of the controlled device based on this data. For example, if there are discrepancies between the physical and virtual devices, which will be reflected in actual operation, the virtual model will be modified accordingly to ensure consistency in appearance, behavior, and operational logic. This adjustment not only affects the model's static properties (such as device appearance and size), but also its dynamic characteristics (such as movement speed and action sequence), ensuring that the virtual model accurately reflects the actual operation of the physical device under the control of different PLC programs.

[0061] In this way, the 3D visualization layer integrates the real operating data of the physical equipment into the display and simulation of the virtual model, further enhancing the authenticity and practicality of the virtual debugging system. It allows operators and engineers to more accurately observe, analyze and optimize the control effect of the PLC program on the equipment in a virtual environment, realizing an effective combination of virtual and reality.

[0062] The method embodiments of the present application can be implemented by the system embodiments of the present application. For details not disclosed in the method embodiments of the present application, please refer to the system embodiments of the present application.

[0063] Reference Figure 4 The present application provides a conveyor line digital twin virtual debugging method based on B / S architecture, comprising the following steps: S401, deploying the PLC simulation layer, business logic layer, and 3D visualization layer on the server side; S402: Writing a PLC program in the PLC programming submodule, running the PLC program in the PLC simulation layer, simulating the PLC program, obtaining a feedback signal from the controlled device, simulating the PLC control logic for the controlled device based on the feedback signal, and sending a control signal to the business logic layer; S403, receiving the control signal generated by the PLC program simulation through the business logic layer, and realizing asynchronous transmission and decoupling of signals between the PLC simulation layer, the business logic layer and the 3D visualization layer through a preset message middleware; S404, updating the operating status of the virtual model of the controlled device according to the calculation result of the business logic layer through the three-dimensional visualization layer, and displaying it in the client browser; S405 , simulating the detection logic of the sensor in the virtual scene, and generating corresponding sensor signals, which are fed back to the PLC simulation layer through the message middleware, forming a closed-loop signal feedback link, and realizing two-way interaction between the virtual model and the PLC program.

[0064] In some embodiments, the further step further includes: the business logic layer implementing asynchronous transmission and decoupling of signals between the PLC simulation layer, the business logic layer, and the three-dimensional visualization layer through the following steps: The business logic layer converts the control signal generated by the PLC program simulation into a message in a preset format and sends it to the message middleware; The message middleware caches the message and forwards the message to a corresponding target module according to a preset routing rule; wherein the target module includes at least one of a PLC simulation layer and a business logic layer; The target module receives the message from the message middleware and performs corresponding processing.

[0065] Obtaining data information obtained by running the PLC program on the physical device of the controlled device; The virtual model of the controlled device is adjusted based on the data information.

[0066] To sum up, in the solution provided by this application, a three-layer B / S architecture consisting of a PLC simulation layer → a business logic layer → a three-dimensional visualization layer is constructed, and each layer realizes asynchronous decoupling of signals and data through Redis.

[0067] Based on digital twin technology, a virtual debugging scene with a 1:1 mapping of the physical production line is established in the front-end three-dimensional virtual environment, and two-way interaction between physical equipment and virtual models is achieved through the modular simulation method of industrial sensors.

[0068] The specific process is as follows: the virtual device action triggers the sensor (such as a photoelectric sensor) in the front-end virtual scene, generating a Boolean signal consistent with the real PLC signal; this signal is fed back to the virtual PLC control logic in real time through the message middleware, driving the back-end to generate motion scripts and update the three-dimensional model status, forming a closed-loop control link of "virtual device action → front-end sensor trigger → PLC response → model update", meeting the core requirements of high-precision replication simulation in the full life cycle management of digital twins.

[0069] The core of the technology in this application is: simulation signal closed-loop feedback mechanism: a closed-loop mechanism of "device action → sensor trigger → PLC response → model update", including signal trigger priority determination rules and status feedback timing synchronization technology. Support for three-layer B / S asynchronous architecture for virtual debugging: a layered collaborative architecture of PLC simulation layer, business logic layer and three-dimensional visualization layer, especially the cross-layer asynchronous transmission mechanism of control signals, device status and model data through message middleware. Multi-source signal millisecond-level synchronization technology: a global timestamp alignment method for virtual-real synchronization of digital twins, combined with the spatiotemporal consistency verification rules of physical device signals and virtual sensor events, to ensure that the cross-layer signal transmission delay is ≤20ms.

[0070] In some embodiments, the key aspects of modular simulation of industrial sensors in a 3D virtual environment include: In 3D scenes like Three.js, this system uses ray detection, collision detection, and position threshold range triggering technologies to simulate the trigger logic of sensors that output Boolean values ​​(True / False), such as photoelectric sensors, proximity switches, and paddle switch sensors. It supports visual configuration of sensor type, installation location, and trigger thresholds (such as detection distance and sensitivity), achieving a high degree of simulation of physical sensors.

[0071] The digital twin sensor library includes virtual models of many common industrial sensors and their corresponding triggering algorithms, such as photoelectric sensors, proximity switches, and paddle switches. Each virtual sensor model is carefully designed based on the characteristics and functions of a real sensor, accurately simulating its behavior and response patterns in actual industrial scenarios.

[0072] The system's visual configuration feature greatly facilitates user operation, allowing users to set the order of sensors in the virtual environment with a simple drag-and-drop operation. Users can complete sensor layout and configuration through an intuitive graphical interface without writing complex code. The system automatically generates Boolean signals based on user-defined configuration parameters. These signals follow user-defined rules and are accurately written to the designated DB (data block) address of the PLC, enabling real-time control and feedback of the PLC program.

[0073] To ensure the accuracy and reliability of sensor signals, the system employs advanced abnormal signal filtering. This method effectively suppresses false triggering caused by model jitter or other interference factors. Users can set the sensor's jitter threshold based on actual needs. The system only considers a valid trigger signal when the sensor detects consistent results multiple times in a row. This significantly reduces false signals caused by external interference or model instability, improving the stability and reliability of the entire system.

[0074] Based on the requirements of digital twin virtual commissioning, an automated mapping link is built between the front-end Three.js 3D scene and back-end device instances. After users configure parameters such as the size, motion logic, conveying direction, and sensor location of device models (such as roller conveyors, elevators, and transfer machines) in the front-end 3D visualization environment, the system automatically generates a structured configuration file (JSON / XML format). This is dynamically instantiated into a runnable device object through the SpringBoot back-end parsing engine, forming a management process of "3D configuration → digital twin generation → virtual commissioning verification."

[0075] In the back-end configuration file generated by the front-end simulation environment, different configuration parameters are automatically generated for different types of devices to adapt to the back-end object motion position calculation function.

[0076] Specifically, the configuration-instance automatic conversion mechanism for digital twins: the front-end three-dimensional model parameters (size, path points, connection relationships) automatically generate a structured configuration file, and are dynamically instantiated into a technical path for an executable device object through the back-end parsing engine.

[0077] This mechanism automates the conversion process from virtual model configuration to operational device objects. Specifically, within the front-end 3D modeling environment, designers can intuitively configure the parameters of the 3D model of the conveyor line equipment, including key information such as equipment dimensions, path point distribution along the conveyor line, and inter-device connectivity. Once these parameters are configured, the system automatically generates structured configuration files from these 3D model parameters, such as those in common JSON or XML formats. These configuration files contain detailed information about the device parameters in a structured format, providing the data foundation for subsequent device instantiation. On the back-end, a parsing engine is deployed, whose primary responsibility is to read and parse the configuration files generated by the front-end. This parsing allows the back-end to understand the various device parameters and their relationships, and dynamically create the corresponding operational device objects based on this information. This process eliminates the need for extensive manual code to define device objects, significantly improving development and debugging efficiency while reducing errors that can occur due to manual operation. Once instantiated, the device object can be activated and used in the virtual commissioning system to simulate and debug device behavior.

[0078] The dynamic digital twin parameter binding method maintains automated mapping rules between device parameters (such as speed and device link relationships) in the backend configuration file and backend device class attributes. This includes differentiated parameter loading logic based on device type, reducing the cost of reconfiguring the debugging environment. This method focuses on ensuring that device parameters in the backend configuration file are accurately and automatically mapped to the backend device class attributes. The backend configuration file stores various device parameters, such as the operating speed of conveyor line equipment and the link relationships between devices. Using predefined mapping rules, the system automatically binds configuration file parameters to the corresponding attributes in the backend device class. This binding is automated, requiring no manual intervention, significantly improving configuration accuracy and efficiency. This method also specifically considers parameter differences between different device types. Differentiated parameter loading logic is used for different types of equipment. For example, different functional equipment, such as roller conveyors and transfer machines, may have different parameter requirements and configuration methods. The system automatically loads and applies the appropriate parameter configuration logic based on the device type, ensuring that each device object is correctly initialized and operates according to its type. This differentiated processing based on device type further enhances the system's flexibility and adaptability. In this way, the dynamic binding of digital twin parameters not only simplifies the reconstruction process of the equipment debugging environment but also reduces related costs. When the conveyor line needs to be adjusted or expanded, simply update the 3D model parameters and regenerate the configuration file on the front end. The back end automatically updates the equipment object parameters based on the new configuration file, eliminating the need for large-scale modification and redeployment of the back end code. This enables the entire system to respond more quickly to equipment changes or process adjustments, improving the overall flexibility and efficiency of the system.

[0079] The back-end object motion position calculation includes: Equipment Management and PLC Signal Synchronization: Based on equipment motion status signals, the system calculates the movement positions of all cargo on a single unit. The conveyor path is abstracted into a parameterized line segment model, and cargo displacement is solved in real time using kinematic equations. Custom configurations are supported for various acceleration modes, including uniform, variable, and pulsed acceleration, enabling arbitrary curve changes such as emergency stops, variable speeds, and reciprocating motion. Cargo positions are dynamically mapped to three-dimensional spatial coordinates based on the path scale factor, ensuring high-precision simulation of the motion trajectory of all cargo during operation and real-time state synchronization, meeting the needs of flexible motion control in complex working conditions.

[0080] Calculate the transfer and transportation of goods in connected equipment based on the equipment movement status signal According to the device motion state signal, the computing device sensor calculates in real time WebSocket communication pushes the real-time location information of all objects to the front end, and pushes the real-time status information of all sensors to the front end Cargo dynamic position calculation method: A real-time cargo position calculation algorithm based on PLC instructions (speed, direction) and equipment parameters (path geometry, dimensions, acceleration curve). This algorithm supports nonlinear motion trajectories (such as speed changes and emergency stops) of cargo on a single device path and continuity verification of paths between multiple devices. Back-end position calculation functionality, comprised of dynamic cargo position calculation methods and inter-device cargo transfer rules, automatically calculates cargo's movement position on the equipment based on PLC instructions (speed / direction) and equipment parameters (size / path), including path connection rules for cross-equipment transfers. Automatically detects the status of adjacent equipment (e.g., current equipment completes transport, next equipment idle), triggers cargo transfers, and converts coordinates to the new equipment's starting point.

[0081] Specifically, the dynamic location calculation method for cargo involves two key aspects: the real-time location calculation of cargo on a single device path, and the location calculation and transfer rules when cargo is transferred between multiple devices. The following is a detailed explanation: The real-time location calculation of goods on a single device path includes: Based on PLC instructions and equipment parameters: By receiving speed and direction information from PLC instructions, as well as path geometry, equipment dimensions, acceleration curves and other data from equipment parameters, a specially designed algorithm is used to calculate the position of goods on a single equipment path in real time.

[0082] Nonlinear motion trajectory support: This algorithm can handle nonlinear motion conditions such as speed changes and sudden stops within a single device path. The algorithm fully considers the impact of acceleration changes on cargo displacement, accurately simulating the actual motion of cargo, ensuring accurate calculation of cargo position under different motion modes.

[0083] The location calculation and transfer rules for goods transfer between multiple devices include: Cross-device routing: When goods need to be transferred from one device to another, the system automatically calculates the goods' movement positions across the different devices based on pre-set rules. This takes into account factors such as the relative position of the two devices and the geometry of the path, ensuring smooth and accurate transfer of goods from one device's endpoint to the next.

[0084] Adjacent device status detection and cargo transfer triggering: The system monitors the status of adjacent devices in real time, such as whether the current device has completed its transport task and whether the next device is idle. When the transfer conditions are met, the system automatically triggers the cargo transfer process and converts the cargo coordinates to the starting coordinate system of the new device, ensuring seamless connection between different devices.

[0085] In summary, the solution proposed in this application utilizes a layered asynchronous architecture (PLC simulation layer → business logic layer → 3D visualization layer), achieving decoupled signal transmission through Redis message-based middleware. This approach constructs a closed-loop link from "device action → sensor trigger → PLC response → model update," combining priority determination with spatiotemporal consistency verification rules to ensure the timing accuracy of signal feedback. Compared to the one-way signal transmission interaction between PLC and digital twin systems in other digital twin simulation systems, this application implements a bidirectional closed-loop mechanism for signal information between virtual commissioning and real devices, improving the reliability of logic verification for virtual commissioning in this application's digital twin.

[0086] This application generates structured configuration files (JSON / XML) based on the Three.js front-end visualization interface, dynamically instantiates device objects through the SpringBoot parsing engine, and establishes an automated mapping link from "3D configuration to digital twin generation." This supports differentiated loading of device dimensions, paths, and sensor parameters. Compared to the inconvenient solution of restarting the entire system when changing configuration in a digital twin simulation system based on the CS architecture, this application supports dynamic configuration of device parameters and their real-time effectiveness, significantly improving the efficiency of debugging scenario reconstruction and reducing the operational and maintenance costs of collaborative debugging of multiple devices.

[0087] The conveying path is abstracted into a parametric mathematical model, and kinematic equations are used to solve cargo displacement. A path continuity verification algorithm is used to achieve seamless cross-device coordinate integration, and the WebSocket protocol is used to synchronize cargo position and device status to a 3D visualization layer. This application uses PLC instructions and parameters such as device speed and acceleration, and performs position calculations based on incremental time, which better conforms to actual motion patterns and achieves high-precision simulation.

[0088] Integrated raycaster, bounding box, and multi-frame filtering algorithms simulate the installation location and detection logic of photoelectric / proximity switches. Supports visual configuration of sensor sensitivity and jitter thresholds, achieving highly consistent mapping between Boolean signals and physical devices. This overcomes the shortcomings of simplified simulations based on device state variables, improving the accuracy and environmental adaptability of sensor signal generation.

[0089] Below, reference Figure 5 To describe the electronic device according to the embodiment of the present application. Figure 5 The figure shows a block diagram of an electronic device according to an embodiment of the present application.

[0090] like Figure 5 As shown, electronic device 500 includes one or more processors 510 and memory 520 .

[0091] The processor 510 may be a central processing unit (CPU) or other forms of processing units having data processing capabilities and / or instruction execution capabilities, and may control other components in the electronic device 500 to perform desired functions.

[0092] The memory 520 may include one or more computer program products, which may include various forms of computer-readable storage media, such as volatile memory and / or non-volatile memory. The volatile memory may include, for example, random access memory (RAM) and / or cache memory. The non-volatile memory may include, for example, read-only memory (ROM), a hard disk, flash memory, etc. One or more computer program instructions may be stored on the computer-readable storage medium, and the processor 510 may execute the program instructions to implement the B / S architecture-based conveyor line digital twin virtual commissioning method of the various embodiments of the present application described above and / or other desired functions. The computer-readable storage medium may also store various contents, such as category correspondences.

[0093] In one example, the electronic device 500 may further include an input device 530 and an output device 540 , and these components are interconnected via a bus system and / or other forms of connection mechanisms (not shown).

[0094] In addition, the input device 530 may also include, for example, a keyboard, a mouse, an interface, etc. The output device 540 may output various information to the outside, including analysis results, etc. The output device 540 may include, for example, a display, a speaker, a printer, a communication network and its connected remote output device, etc.

[0095] Of course, to simplify, Figure 5 Only some of the components in the electronic device related to the present application are shown, and components such as a bus, an input / output interface, etc. are omitted. In addition, the electronic device may further include any other appropriate components according to specific application scenarios.

[0096] In addition to the above-mentioned methods and devices, an embodiment of the present application may also be a computer program product, which includes computer program instructions, which, when executed by a processor, enable the processor to execute the steps of the conveyor line digital twin virtual debugging method based on the B / S architecture according to various embodiments of the present application described in the above "Exemplary Method" section of this specification.

[0097] The computer program product may be written in any combination of one or more programming languages ​​to implement the program code for performing the operations of the embodiments of the present application, including object-oriented programming languages ​​such as Java, C++, and conventional procedural programming languages ​​such as "C" or similar programming languages. The program code may be executed entirely on the user's computing device, partially on the user's computing device, as a standalone software package, partially on the user's computing device and partially on a remote computing device, or entirely on a remote computing device or server.

[0098] In addition, an embodiment of the present application may also be a computer-readable storage medium having computer program instructions stored thereon, which, when executed by a processor, enables the processor to execute the steps of the digital twin virtual debugging method of a conveyor line based on a B / S architecture according to various embodiments of the present application described in the above "Exemplary Method" section of this specification.

[0099] The computer-readable storage medium may be any combination of one or more readable media. The readable medium may be a readable signal medium or a readable storage medium. The readable storage medium may include, for example, but is not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, device, or device, or any combination thereof. More specific examples (a non-exhaustive list) of readable storage media include: an electrical connection with one or more wires, a portable disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disk read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination thereof.

[0100] The above description has been provided for the purpose of illustration and description. Furthermore, this description is not intended to limit the embodiments of the present application to the forms disclosed herein. Although a number of example aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, alterations, additions, and sub-combinations thereof.

Claims

1. A conveyor line digital twin virtual debugging system based on B / S architecture, characterized by: It includes a three-layer B / S architecture consisting of a PLC simulation layer, a business logic layer, and a 3D visualization layer; PLC simulation layer: used to run and simulate PLC programs, obtain feedback signals from controlled devices, simulate the PLC's control logic for the controlled devices based on the feedback signals, and send control signals to the business logic layer. Asynchronous decoupled communication is implemented between the PLC simulation layer and the business logic layer via message-based middleware. a business logic layer, communicatively connected to the PLC simulation layer, configured to obtain the control signal, and perform business logic operations based on the control signal and the feedback signal to calculate the motion of the simulated controlled device to obtain real-time position data; and transmit the real-time position data to the 3D visualization layer, wherein the business logic layer and the 3D visualization layer are connected via a real-time persistent connection communication protocol; Three-dimensional visualization layer: Communicating with the business logic layer, it is used to display the operating status of the controlled device based on the pre-built virtual model of the controlled device and the real-time position data to show the operating results of the PLC program, and generate feedback signals based on the virtual sensors on the virtual model of the controlled device and send them to the business logic layer.

2. The conveyor line digital twin virtual debugging system based on B / S architecture according to claim 1 is characterized by: The PLC simulation layer includes: PLC programming submodule: used to write the PLC program; PLC simulation submodule: used to simulate the PLC program to simulate the control logic of the PLC on the controlled device.

3. The conveyor line digital twin virtual commissioning system based on B / S architecture according to claim 1 is characterized by: The business logic layer includes: Signal processing submodule: used for processing the control signal generated by the PLC program simulation and the feedback signal from the controlled device; Business logic operation submodule: used to perform business logic operation according to the signal processed by the signal processing submodule; Configuration management submodule: used to manage the configuration information of the controlled device and generate the corresponding controlled device according to the configuration information; Kinematics calculation submodule: used to calculate the motion state of the controlled device according to the calculation results of the business logic calculation submodule and the dynamic model of the controlled device to obtain real-time position data.

4. The conveyor line digital twin virtual debugging system based on B / S architecture according to claim 1 is characterized by: The three-dimensional visualization layer includes: Scenario construction submodule: used to build a virtual model of the controlled device; Model loading and updating submodule: used to load the virtual model of the controlled device in the virtual scene and update the operating status of the virtual model according to the real-time location data of the business logic layer; The sensor simulation submodule is used to simulate the detection logic of the sensor in the virtual scene and generate a corresponding sensor signal; wherein the sensor signal is a feedback signal.

5. The conveyor line digital twin virtual debugging system based on B / S architecture according to claim 1 is characterized by: The business logic layer and the three-dimensional visualization layer communicate using the WebSocket protocol to achieve real-time data transmission; Redis message queue is used between the PLC simulation layer and the business logic layer to achieve asynchronous decoupling of signals and data.

6. The conveyor line digital twin virtual commissioning system based on B / S architecture according to claim 1 is characterized by: The three-dimensional visualization layer is further used to: obtain data information obtained by running the PLC program on a physical device of the controlled device; and adjust the virtual model of the controlled device based on the data information.

7. A digital twin virtual debugging method for a conveyor line based on B / S architecture, characterized in that: The method comprises the following steps: Deploy the PLC simulation layer, business logic layer, and 3D visualization layer on the server side; The PLC program is written in the PLC programming submodule and is used to run the PLC program in the PLC simulation layer. The PLC program is simulated to obtain feedback signals from the controlled devices. Based on the feedback signals, the PLC control logic of the controlled devices is simulated and control signals are sent to the business logic layer. The control signal generated by the PLC program simulation is received through the business logic layer, and the signal asynchronous transmission and decoupling between the PLC simulation layer, the business logic layer and the three-dimensional visualization layer are realized through the preset message middleware; updating the operating status of the virtual model of the controlled device according to the calculation results of the business logic layer through the three-dimensional visualization layer and displaying it in the client browser; The detection logic of the sensor is simulated in the virtual scene, and the corresponding sensor signal is generated and fed back to the PLC simulation layer through the message middleware, forming a closed-loop signal feedback link, and realizing two-way interaction between the virtual model and the PLC program.

8. The method for virtual debugging of a digital twin of a conveyor line based on a B / S architecture according to claim 7 is characterized in that: The business logic layer implements asynchronous signal transmission and decoupling between the PLC simulation layer, the business logic layer, and the three-dimensional visualization layer through the following steps: The business logic layer converts the control signal generated by the PLC program simulation into a message in a preset format and sends it to the message middleware; The message middleware caches the message and forwards the message to a corresponding target module according to a preset routing rule; wherein the target module includes at least one of a PLC simulation layer and a business logic layer; The target module receives the message from the message middleware and performs corresponding processing.

9. The method for virtual debugging of a digital twin of a conveyor line based on a B / S architecture according to claim 7 is characterized in that: Also includes: Obtaining data information obtained by running the PLC program on the physical device of the controlled device; The virtual model of the controlled device is adjusted based on the data information.

10. An electronic device, characterized in that: include: A processor, and a memory for storing a program executable by the processor; The processor is used to implement the conveyor line digital twin virtual debugging method based on B / S architecture as described in any one of claims 7 to 9 by running the program in the memory.

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