Digital twinborn model-oriented virtual-real combination test device and test method

Abstract

The invention discloses a virtual-real combination test device and a virtual-real combination test method for a digital twin model, and relates to the technical field of digital twin model tests. The test device comprises a test bench, a driving platform, a load loading module, a control assembly and an upper computer. The driving platform is connected with the test bed, a first flange block is arranged on the driving platform, a second flange block is arranged on the test bed, and load loading modules are arranged on the first flange block and the second flange block; the upper computer constructs a virtual prototype model based on digital twinning; the control assembly is used for operating the virtual prototype model and obtaining virtual simulation signal data of a node corresponding to the to-be-tested piece, and the control assembly is used for controlling the driving platform and the load loading module to act according to the virtual simulation signal data. According to the invention, the test work can be carried out for typical components with high fault probability in the mechanism, and the test preparation period and the test cost can be effectively shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of digital twin model testing, and in particular to a virtual-reality combined testing device and a testing method for digital twin models. Background Art

[0002] Traditional physical testing methods for complex aircraft mechanisms, such as landing gear retraction and extension tests, often require the construction of complex test equipment and a complete test assembly for the mechanism under test. Furthermore, the operating environment of the landing gear mechanism is complex and highly variable during an aircraft's service life. Traditional test platforms can only simulate the mechanism's motion under specific conditions, requiring repeated adjustments and changes to test conditions to simulate different complex conditions. This includes changing hydraulic oil pressure, hydraulic line connections, and drive module logic. Furthermore, the test piece's installation position is typically fixed within a given test cycle, preventing flexible adjustment or replacement, significantly limiting test flexibility. Traditional testing methods suffer from low efficiency, long cycles, and high costs.

[0003] With the continuous development of aviation technology, the testing requirements for complex mechanisms are becoming increasingly stringent. Traditional test benches have shortcomings in simulating the actual movement of mechanisms. For example, a real landing gear not only needs to be lowered and locked in various wind conditions, but also often experiences the real movement conditions of drop shock, rolling loads, and turning loads after being lowered before being retracted.

[0004] In response to the problems existing in the above-mentioned existing technologies, technical personnel in this field urgently need a virtual-reality combined test device and test method for digital twin models, so as to simulate a test bench in which multiple working conditions can alternate in a short period of time, so as to more comprehensively test the characteristics of key mechanisms such as landing gear. Summary of the Invention

[0005] The purpose of the present invention is to provide a virtual-reality combined test device and test method for digital twin models to solve the problems existing in the above-mentioned prior art. It can carry out test work on typical components with a higher probability of failure in the mechanism, and can effectively shorten the test preparation cycle and test cost. It can quickly and accurately simulate various complex working conditions for key test components of the mechanism.

[0006] To achieve the above object, the present invention provides the following solutions:

[0007] In a first aspect, the present invention provides a virtual-reality combined test device for digital twin models, comprising a test bench, a drive platform, a load loading module, a control component and a host computer; the drive platform is connected to the test bench, a first flange block is provided on the drive platform, and the drive platform is used to drive the first flange block to move, a second flange block is provided on the test bench, and the first flange block and the second flange block are both provided with the load loading module, and the load loading module is used to apply a load to the test piece; the host computer is constructed with a virtual prototype model based on the digital twin; the drive platform, the load loading module and the host computer are all connected to the control component; the control component is used to run the virtual prototype model and obtain virtual simulation signal data of the node corresponding to the test piece, and the control component is used to control the action of the drive platform and the load loading module according to the virtual simulation signal data.

[0008] In some embodiments, the control component is also used to collect the physical signal data of the drive platform and the load loading module and calculate the error between the physical signal data and the virtual simulation signal data; the host computer is used to synchronously adjust the virtual prototype model in real time according to the error between the physical signal data and the virtual simulation signal data.

[0009] In some embodiments, the driving platform includes an X-axis driving component, a Y-axis driving component and a Z-axis driving component; the Z-axis driving component includes a first platform, a first screw-nut transmission component, a first driving device and a first encoder, the first screw-nut transmission component is vertically arranged and connected to the test bench, the first driving device is used to drive the first screw-nut transmission component to move, one end of the first screw-nut transmission component is connected to the first encoder, and the first platform arranged horizontally is provided on the first screw-nut transmission component; the X-axis driving component includes a second platform, a second screw-nut transmission component, a second driving device and a second encoder, and the second screw-nut transmission component is horizontally arranged Placed on the first platform, the second drive device is used to drive the second screw-nut transmission assembly to move, the second encoder is provided at one end of the second screw-nut transmission assembly, and the second platform is provided horizontally; the Y-axis drive assembly includes a guide rail assembly, the guide rail assembly is connected to the second platform, the guide rail assembly is horizontally arranged and perpendicular to the second screw-nut transmission assembly, and the first flange block is slidably connected to the guide rail assembly; an acceleration sensor is provided on the first flange block, and the acceleration sensor, the first encoder, the second encoder, the first drive device and the second drive device are all connected to the control assembly.

[0010] In some embodiments, the load loading module includes at least two mutually perpendicular loading components, each of the loading components includes a third drive device and a force sensor, the output shaft of the third drive device is connected to one end of the force sensor, and the other ends of at least two mutually perpendicular force sensors are hinged to the end of the test piece; the force sensor and the third drive device are both connected to the control component.

[0011] In some embodiments, the control component includes a control system, a real-time simulation system, an execution system, a signal acquisition system and a signal conditioning system; the control system is used to send a first control instruction to the real-time simulation system, the real-time simulation system is used to run the virtual prototype model and obtain the simulated load parameters and simulated motion parameters of the node corresponding to the test piece and feed them back to the control system; the control system is also used to send a second control instruction to the execution system, the execution system is used to drive the load driving module to load according to the simulated load parameters and to drive the driving platform to move according to the simulated motion parameters; the signal acquisition system is used to collect physical sensor signals and send them to the real-time simulation system, and the signal conditioning system is used to process the physical sensor signals.

[0012] In some embodiments, the control system includes a controller, a D / A converter and a control algorithm unit; the real-time simulation system includes a real-time processor, an I / O interface board, a fault injection module and a simulation software unit, and the fault injection module is used to simulate fault conditions; the signal acquisition system includes a data acquisition card, a data storage module and an A / D converter, and the data acquisition card is used to acquire the physical sensor signal; the signal conditioning system includes an amplifier and a filter.

[0013] In some embodiments, the Z-direction drive assembly includes four first screw-nut transmission assemblies, and one end of two of the first screw-nut transmission assemblies are respectively connected to the corresponding first drive devices, and one end of the other two first screw-nut transmission assemblies are respectively provided with a first synchronization wheel, and the two first drive devices correspond one-to-one to the two first synchronization wheels and are connected through belt transmission; the X-direction drive assembly includes two second screw-nut transmission assemblies, and one end of one of the second screw-nut transmission assemblies is connected to the second drive device, and one end of the other second screw-nut transmission assembly is provided with a second synchronization wheel, and the second drive device and the second synchronization wheel are connected through belt transmission.

[0014] In the second aspect, the present invention provides a virtual-reality combined test method for digital twin models, using the above-mentioned virtual-reality combined test device for digital twin models, including the following steps: connecting the test piece to the load loading modules on the first flange block and the second flange block respectively; the control component runs the virtual prototype model and obtains virtual simulation signal data of the node corresponding to the test piece; the control component controls the driving platform to drive the first flange block to move and controls the load loading module to load the test piece according to the virtual simulation signal data.

[0015] In some embodiments, it also includes: a control component collecting the physical signal data of the driving platform and the load loading module and calculating the error between the physical signal data and the virtual simulation signal data; judging whether the error between the physical signal data and the virtual simulation signal data is greater than a threshold; if so, the upper computer synchronously adjusts the virtual prototype model in real time according to the error between the physical signal data and the virtual simulation signal data.

[0016] In some embodiments, the step of "calculating the error between the physical signal data and the virtual simulation signal data" includes: the control component performs noise reduction processing on the collected physical signal data and normalizes the noise-reduced data; the control component calculates the distance between the data points in the time series between the physical signal data and the virtual simulation signal data, and constructs a distance matrix; the control component uses a dynamic programming algorithm to find a path with the minimum cumulative distance in the distance matrix and aligns the physical signal data with the virtual simulation signal data according to the path; the control component calculates the error between the aligned physical signal data and the virtual simulation signal data.

[0017] Compared with the prior art, the present invention has achieved the following technical effects:

[0018] The virtual-reality combined test device and test method for digital twin models of the present invention installs the test piece on the load loading module on the first flange block and the second flange block, applies a load to the test piece through the load loading module, and drives the first flange block and the test piece to move through the driving platform; a virtual prototype model is built on the host computer, and the virtual prototype model corresponds to a complete mechanism prototype model including the test piece; thus, the present invention can run the complete mechanism prototype digital twin model on the virtual end and run the typical components of the complete mechanism, i.e., the test piece, on the physical experimental platform; based on the virtual simulation signal data of the digital twin model and using the control technology of the virtual model, the physical test platform is controlled to provide multi-degree-of-freedom force loading and motion simulation for the test object, and control the driving platform and the load loading module to simulate the spatial position changes and force loading at both ends of the test component, thereby simulating complex actual working conditions and improving test efficiency; that is, the present invention can carry out testing work on typical components with a higher probability of failure in the mechanism, and can effectively shorten the test preparation cycle and test cost, and can quickly and accurately simulate various complex working conditions for key test components of the mechanism. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 Schematic diagram of the structure of a virtual-reality combined test device for a digital twin model in some embodiments of the present invention;

[0021] Figure 2 This is a front view of a virtual-reality combined test device for a digital twin model in some embodiments of the present invention;

[0022] Figure 3 A side view of a virtual-reality combined test device for a digital twin model in some embodiments of the present invention;

[0023] Figure 4 A top view of a virtual-reality combined test device for a digital twin model in some embodiments of the present invention;

[0024] Figure 5 Schematic diagram of the working principle of a virtual-reality combined test device for a digital twin model in some embodiments of the present invention;

[0025] Figure 6 A block diagram of the main components of a virtual-reality combined test device for a digital twin model in some embodiments of the present invention;

[0026] Figure 7 A schematic diagram of a flow chart of data interaction between a real-time simulation system and a host computer in some embodiments of the present invention;

[0027] Figure 8 A schematic diagram of a process for performing data error analysis using a simulation system in some embodiments of the present invention;

[0028] Figure 9 This is a flow chart of the main steps of the virtual-reality combined testing method for digital twin models in some embodiments of the present invention.

[0029] In the figure: 1-test bench; 2-control cabinet; 3-first screw and nut transmission assembly; 4-host computer; 5-workbench; 6-stepping motor; 7-first bracket; 8-toothed synchronous belt; 9-ball nut; 10-first platform; 11-second platform; 12-coupling; 13-second encoder; 14-second bracket; 15-guide rail; 16-limit nut; 17-rigid bushing; 18-first flange block; 19-test piece; 20-servo electric cylinder; 21-second flange block; 22-connecting ear; 23-force sensor; 24-acceleration sensor; 25-second synchronous wheel; 26-power supply; 27-inertial measurement unit. DETAILED DESCRIPTION

[0030] 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. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0031] The purpose of the present invention is to provide a virtual-reality combined test device and test method for digital twin models to solve the problems existing in the prior art. It can carry out test work on typical components with a higher probability of failure in the mechanism, and can effectively shorten the test preparation cycle and test cost. It can quickly and accurately simulate various complex working conditions for key test components of the mechanism.

[0032] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0033] The present invention provides a virtual-reality combined test device for digital twin models, such as Figures 1 to 7As shown, it includes a test bench 1, a drive platform, a load loading module, a control component and a host computer 4; wherein, the drive platform is connected to the test bench 1, and a first flange block 18 is provided on the drive platform, and the drive platform is used to drive the first flange block 18 to move; a second flange block 21 is provided on the test bench 1, and a load loading module is provided on both the first flange block 18 and the second flange block 21, and the load loading module is used to apply a load to the test piece 19.

[0034] It should be noted that the first flange block 18 of the embodiment of the present invention is a movable flange block, and the second flange block 21 is a fixed flange block; the test piece 19 is a planar connecting rod structure, for example, the test piece 19 can be a planar connecting rod mechanism of the lower strut lock of the landing gear.

[0035] A virtual prototype model is constructed in the host computer 4 based on the digital twin technology. The virtual prototype model is a digital twin model of a complete mechanism prototype including the test piece 19 .

[0036] The driving platform, load loading module and host computer 4 are all connected to the control component; the control component is used to run the virtual prototype model and obtain virtual simulation signal data of the node corresponding to the test piece 19, and the control component controls the movement of the driving platform and controls the loading action module to load according to the virtual simulation signal data.

[0037] It should be noted that the virtual platform of the present invention is constructed based on the digital twin model. It builds a virtual prototype model of a complete and complex planar linkage mechanism based on the rigid-flexible coupling dynamics method. It can simulate the dynamic behavior of the entire set of virtual prototype models in real time and extract the motion and load conditions of the tested components or assemblies; the calculation results of the virtual model are transmitted to the control component in real time to control the motion of the screw-driven linear platform and the load of the servo electric cylinder loading module, thereby realizing the control of the node position and force at both ends of the linkage mechanism.

[0038] In some embodiments, the control component is further configured to collect physical signal data of the driving platform and the load loading module and calculate an error between the physical signal data and the virtual simulation signal data.

[0039] The host computer 4 is used to adjust the virtual prototype model in real time and synchronously according to the error between the physical signal data and the virtual simulation signal data.

[0040] It should be noted that the present invention needs to synchronously adjust the virtual prototype model when the error between the physical signal data and the virtual simulation signal data is greater than the threshold; here, the physical signal data is the data collected by the sensor system and transmitted to the virtual prototype model in the host computer 4 in real time and the state and parameters of the model are updated.

[0041] In some embodiments, the driving platform includes an X-axis driving component, a Y-axis driving component, and a Z-axis driving component; Figure 1As shown, the Z direction is the vertical direction, and the X and Y directions are horizontal directions and perpendicular to each other.

[0042] The Z-direction drive assembly includes a first platform 10, a first screw-nut transmission assembly 3, a first drive device and a first encoder. The first screw-nut transmission assembly 3 is arranged vertically and connected to the test bench 1. The first drive device is used to drive the first screw-nut transmission assembly 3 to move. One end of the first screw-nut transmission assembly is connected to the first encoder. A horizontally arranged first platform 10 is provided on the first screw-nut transmission assembly.

[0043] The X-axis drive assembly includes a second platform 11, a second screw-nut transmission assembly, a second drive device and a second encoder 13. The second screw-nut transmission assembly is horizontally arranged on the first platform 10. The second drive device is used to drive the second screw-nut transmission assembly to move. A second encoder 13 is arranged at one end of the second screw-nut transmission assembly, and a horizontally arranged second platform 11 is arranged on the second screw-nut transmission assembly.

[0044] The Y-axis driving assembly includes a guide rail assembly, which is connected to the second platform 11. The guide rail assembly is horizontally arranged and perpendicular to the second screw nut transmission assembly. The first flange block 18 is slidably connected to the guide rail assembly.

[0045] An acceleration sensor 24 is provided on the first flange block 18 , and the acceleration sensor 24 , the first encoder, the second encoder 13 , the first drive device and the second drive device are all connected to the control assembly.

[0046] It should be noted that the first drive device and the second drive device of the present invention are both stepper motors 6, and the first screw-nut transmission assembly 3 and the second screw-nut transmission assembly both include adaptably connected screws and ball nuts 9; the first screw-nut transmission assembly 3 is connected and fixed to the column of the test bench 1 through the first bracket 7, one end of the first screw-nut transmission assembly 3 is connected to the first encoder through the first coupling, and the first encoder is connected and fixed to the column of the test bench 1 through the corresponding bracket; one end of the second screw-nut assembly is connected to the second encoder 13 through the second coupling 12, and the second encoder 13 is connected and fixed to the first platform 10 through the second bracket 14.

[0047] The Y-axis drive assembly of the present invention includes two groups of guide rail assemblies arranged in parallel, and each group of guide rail assemblies includes a guide rail 15, a limiting nut 16 and a rigid bushing 17; wherein, the two ends of the circular guide rail 15 pass through the corresponding second platform 11 and are threadedly connected to the limiting nut 16, and the two rigid bushings 17 are sleeved on the circular guide rail 15, and the bottom end of the first flange block 18 is sleeved on the circular guide rail 15. The first flange block 18 is located between the two rigid bushings 17 of each group of guide rail assemblies, and one end of the two rigid bushings 17 abuts against the corresponding second platform 11, and the other end of the two rigid bushings 17 abuts against the two ends of the first flange block 18 for limiting; the present invention can adjust the Y-axis position of the first flange block 18 by adjusting the length of the rigid bushing 17.

[0048] In some embodiments, the Z-direction drive assembly includes four first screw-nut transmission assemblies 3, and one end of two first screw-nut transmission assemblies 3 are respectively connected to the corresponding first drive devices, and one end of the other two first screw-nut transmission assemblies 3 are respectively provided with a first synchronous wheel, and the two first drive devices correspond one-to-one to the two first synchronous wheels and are connected through a toothed synchronous belt 8.

[0049] The X-direction drive assembly includes two second screw-nut transmission assemblies, and one end of one second screw-nut transmission assembly is connected to the second drive device, and one end of the other second screw-nut transmission assembly is provided with a second synchronous wheel 25, and the second drive device and the second synchronous wheel 25 are connected through a toothed synchronous belt 8.

[0050] In some embodiments, the load loading module includes at least two mutually perpendicular loading components, each loading component includes a third drive device and a force sensor 23, the output shaft of the third drive device is connected to one end of the force sensor 23, and the other end of at least two mutually perpendicular force sensors 23 is hinged to the end of the test piece 19; the force sensor 23 and the third drive device are both connected to the control component.

[0051] It should be noted that the third driving device of the present invention is a servo electric cylinder 20, which is fixed to the flange block with bolts and is orthogonally distributed, applying forces in the Y and Z directions respectively; the output end of the electric cylinder is connected to the force sensor 23, and the other end of the force sensor 23 is connected to the connecting ear 22 at the end of the test piece 19 to realize the function of applying an orthogonal force system to the mechanism. Since the two ends of the object to be tested are fixed by hinges, it is only necessary to apply orthogonal forces in a maximum of three directions to simulate the actual force conditions of the object to be tested at the node. For a planar mechanism, it is only necessary to apply orthogonal forces in two directions to simulate the load conditions of the planar mechanism at the node. The virtual prototype model obtains the load conditions at both ends of the tested mechanism through simulation, and controls the servo electric cylinder 20 mechanism through signal feedback.

[0052] In some embodiments, the control component includes a control system, a real-time simulation system, an execution system, a signal acquisition system, and a signal conditioning system.

[0053] The control system is configured to send a first control instruction to the real-time simulation system. The real-time simulation system is configured to run the virtual prototype model and obtain simulated load parameters and simulated motion parameters for the nodes corresponding to the test object, and then feed these back to the control system. The control system is also configured to send a second control instruction to the execution system. The execution system is configured to drive the load drive module to load according to the simulated load parameters and to drive the drive platform to move according to the simulated motion parameters. The signal acquisition system is configured to collect physical sensor signals and transmit them to the real-time simulation system. The signal conditioning system is configured to process the physical sensor signals.

[0054] It should be noted that the main function of the control system is to generate control instructions based on the control algorithm of the stepper motor and electric cylinder and send them to the real-time simulation system, while converting the digital control signal into an analog signal. The control algorithm here is mainly a "displacement-load" matching algorithm based on the mechanism node. For example, in the virtual prototype, when the mechanism moves to 0.7s, the position coordinates of its lower end node are (X 0.7 , Z 0.7 ), at this time the load condition at the node is (Fx, Fz); then it is necessary to adjust the algorithm so that the physical test prototype moves to (X 0.7 , Z 0.7 ) when the loads at both ends are (Fx, Fz).

[0055] The main function of the real-time simulation system is to run the prototype model of the complex mechanism, simulate the dynamic behavior of the complete mechanism, and collect and extract the load and motion conditions at the nodes of the object under test in the virtual end. At the same time, it receives instructions from the control system and calculates the load and motion conditions of the corresponding nodes of the test model, and feeds back the results to the control system.

[0056] The main function of the execution system is to receive instructions from the control system and drive the physical hardware to run.

[0057] The main function of the signal acquisition system is to collect sensor signals, control signals and output signals of the real-time simulation system in the test platform, and convert these analog signals into digital signals; the control signal here refers to the command signal issued by the control system and the feedback signal during the operation of the physical test device. The feedback signal is used for self-adjustment of the control system.

[0058] The main function of the signal conditioning system is to amplify, filter and process the sensor signal to improve the signal quality so that it meets the requirements of data acquisition and analysis.

[0059] In some embodiments, a control system includes a controller, a D / A converter, and a control algorithm unit.

[0060] It should be noted that the controller includes a servo driver for the servo motor and a driver for the stepper motor, which are used to drive the servo electric cylinder to apply the corresponding load and the stepper motor to rotate accordingly to achieve the movement of the test piece node position. The control algorithm unit is a control algorithm based on a load-displacement matching mechanism, that is, the load on the corresponding node of the test piece when it moves to a certain position.

[0061] The real-time simulation system includes a real-time processor, an I / O interface board, a fault injection module, and simulation software. The fault injection module is used to simulate fault conditions. For example, by adding friction to a node in a mechanism to simulate an underlubricated condition, the virtual terminal will detect the mechanism's motion under the underlubricated condition, and correspondingly, the displacement and load data of the mechanism's nodes under this condition. This data is then transmitted to the control system to drive the physical mechanism to perform the corresponding motion. At this point, the load and displacement of the physical mechanism's nodes are in an underlubricated condition. The signal acquisition system includes a data acquisition card, a data storage module, and an A / D converter. The data acquisition card collects physical sensor signals. The signal conditioning system includes an amplifier and a filter.

[0062] It should be noted that the real-time processor of the present invention is used to perform corresponding solution tasks, and the simulation software unit is a virtual model running in the real-time simulation system. After the real-time simulation system receives the operating status of the test piece, it sends the solved data to the simulation software unit to drive the virtual model therein.

[0063] In some embodiments, the detailed components of the host computer 4 of the present invention are: a computer, state monitoring software, and data analysis software. The virtual platform of the present invention adopts a digital twin model, which is constructed based on the rigid-flexible coupling dynamic model of a complex mechanism and contains key information such as the material properties, connection methods, and boundary conditions of the complex mechanism. The virtual model can simulate the dynamic behavior of the complex mechanism in real time and set additional signal collection points at the key node positions of the measured object in the virtual platform to extract the movement and force conditions of the nodes. Here, due to the limited space of the physical test prototype and the inability to arrange enough sensors, virtual sensors can be set in its virtual prototype to monitor some additional required signals. For example, it is difficult to collect the load conditions of the intermediate nodes of the mechanism when they are in motion, but sensors at this location can be set at the virtual end. When the motion state of the physical mechanism is the same as that of the virtual mechanism, it can be approximately considered that the load conditions of the intermediate nodes of the mechanism collected by the virtual end are the same as the real situation. In addition, the virtual model also exchanges data with the physical test platform and adopts a synchronous clock mechanism to ensure that the data of the virtual model and the actual test platform are synchronized in real time.

[0064] like Figure 5 As shown, the control cabinet 2 is connected to a power supply 26. An inertial measurement unit 27 is mounted on the first flange block 18 of the first platform 10. This unit, fixed to the first flange block 18, measures the platform's linear acceleration along three axes. Acceleration integration allows the platform's velocity and displacement to be calculated. Furthermore, the inertial measurement unit 27 detects dynamic responses of the motion platform, such as starting and stopping, for feedback control within the control system.

[0065] like Figure 6 As shown, the signal acquisition end includes a linear displacement sensor, an angle sensor, an encoder, a force sensor 23 and an acceleration sensor 24, wherein the linear displacement sensor and the angle sensor are both arranged on the test piece 19. And Figure 6 In this paper, virtual sensors refer to some acquisition nodes set up in the virtual prototype. For example, the corresponding information can be read at the corresponding virtual end at the location where the sensor is installed on the physical prototype, so that the virtual sensor information can be compared with the physical sensor information. The motion signal of the physical prototype is transmitted through the physical sensor such as Figure 6 The load, displacement, angle sensors, etc. in the virtual prototype will also have corresponding data during the test. These data are sent to a high-performance simulator for comparative analysis. If the gap between the physical signal and the virtual signal is too large, it will indicate that there is a problem with the mechanism movement. At this time, the model parameters need to be adjusted to match.

[0066] The present invention constructs a virtual-reality combined test bench based on the deep integration of virtual test models and physical tests, and constructs a virtual-reality closed-loop test method. The present invention focuses on the key components or assemblies in the complex mechanism being tested, by running the digital twin model of the complete mechanism prototype on the virtual end, running the typical components in the mechanism on the physical test platform, and the sensor system on the physical test end collects data and transmits it to the virtual test platform in real time. The host computer performs error comparison and analysis on the collected entity signal and virtual simulation signal, updates and corrects the virtual simulation model in real time, and controls the physical test platform based on the simulation data of the digital twin model using the control technology of the virtual model, providing multi-degree-of-freedom force loading and motion simulation for the object being tested, and using linear drive pairs and servo electric cylinders to simulate the spatial position changes and force loading at both ends of the component being tested, thereby simulating complex actual working conditions and improving test efficiency.

[0067] The main function of the test bench 1 is to integrate its components. Four sets of first screw-nut drive assemblies are mounted on four main pillars and secured with bolts. The output shafts of two stepper motors 6 are connected to the screw shafts via synchronous pulleys, and the motors are also bolted to the pillars. A control cabinet 2 is bolted to the top side of the main frame. This cabinet houses control and acquisition equipment such as the signal acquisition system, real-time simulator, and control system. Below the control cabinet 2 is an aluminum alloy workbench 5, which primarily houses equipment such as the host computer 4. A square second flange block 21 is bolted to the top crossbeam of the frame. This second flange block 21 does not move or deflect during testing. The main frame and support frame are designed to withstand the primary test loads, and the shape and size of the second flange block 21 can be adjusted according to the spatial motion of the test object. Limit blocks on either side of the screw-nut limit the linear motion of the motion platform to prevent the motion platform from rising too high, compressing the test space below the test object's motion space and damaging the test equipment and the test object.

[0068] The two ends of the test piece 19 are hinged to connecting tabs 22, which are bolted to force sensors 23. One end of the test piece 19 is fixed to the servo electric cylinder loading module on the second flange block 21, and the other end is fixed to the servo electric cylinder load loading module on the first flange block 18, both of which are bolted together. The spatial motion of the test object is transmitted through a relative coordinate system. The second flange block 21 at the top serves as the reference coordinate system, and the first flange block 18 at the bottom moves in accordance with the spatial motion of the motion platform.

[0069] The main function of the lead screw driven linear platform is to drive the motion platform to realize the spatial motion of the motion platform along the X axis and the Z axis. The spatial motion mechanism in the Z direction is composed of four lead screw nut mechanisms and two stepper motors 6, which are fixed on the main support of the test bench 1 and are fixed to the support through bolts. The output shafts of the two stepper motors 6 are connected to the lead screw shafts through synchronous wheels and are also connected to a synchronous wheel at the other lead screw nut mechanism on the same side. The synchronous wheels on the same side are connected through a toothed synchronous belt to ensure the consistency of the motion, realizing the function of driving two lead screw shafts by one stepper motor 6, which is beneficial to the motion control in the Z direction. Since the motion platform also needs to carry a servo cylinder loading module, a combination of one stepper motor 6 and two lead screw nut mechanisms is selected for driving in the X direction. The two lead screw nut mechanisms also use synchronous wheels to cooperate with toothed synchronous belts to ensure the consistency of the motion. The X-axis linear motion system is fixed on the Z-axis ball screw motion component, that is, the X-direction ball screw mechanism as a whole can move with the Z-direction lead screw nut mechanism in the Z direction. Although the test platform is mainly used for testing and testing of planar link mechanisms, in order to ensure the matching of the positions of the measured mechanism and the second flange block 21 and the stability of the spatial motion of the motion platform, a linear guide rail 15 is used to adjust the Y direction position of the moving platform to match the second flange block 21. The motion platform is fixed on the moving part of the X linear motion system, and the whole can move linearly in the X direction. A rotary encoder is installed at the end of each lead screw driven by a stepper motor 6, which is used to measure the lead screw rotation angle information in real time and obtain displacement information. Through position feedback control, the displacement accuracy of the drive is ensured, and the motor speed is controlled in combination with the loading force signal to realize the speed control of the motion platform in the X and Z directions, so as to synchronously track the spatial motion position of the measured object on the test bench and simulate the kinematic performance of the measured object.

[0070] The application also provides a virtual-real combined test method for a digital twin model, as shown in the accompanying drawings, comprising the following steps: Figure 9

[0071] Step S1: connecting the test piece 19 to the load loading module on the first flange block 18 and the second flange block 21 respectively;

[0072] Step S2: controlling the assembly to run the virtual prototype model and obtaining the virtual simulation signal data corresponding to the nodes of the test piece 19;

[0073] Step S3: controlling the driving platform to move the first flange block 18 and controlling the load loading module to load the test piece 19 according to the virtual simulation signal data.

[0074] In some embodiments, as shown in the accompanying drawings, Figure 8 ​As shown, it also includes: a control component collects physical signal data of the driving platform and the load loading module and calculates the error between the physical signal data and the virtual simulation signal data;

[0075] Determine whether the error between the physical signal data and the virtual simulation signal data is greater than a threshold;

[0076] If so, the host computer 4 adjusts the virtual prototype model in real time according to the error between the physical signal data and the virtual simulation signal data.

[0077] In some embodiments, continue to refer to Figure 8 As shown, the step of "calculating the error between the physical signal data and the virtual simulation signal data" includes:

[0078] The control component performs noise reduction processing on the collected entity signal data and performs normalization operation on the noise-reduced data;

[0079] The control component calculates the distance between the data points in the time series between the physical signal data and the virtual simulation signal data, and constructs a distance matrix;

[0080] The control component uses a dynamic programming algorithm to find a path with the minimum cumulative distance in the distance matrix and aligns the physical signal data with the virtual simulation signal data according to the path;

[0081] The control component calculates the error between the aligned physical signal data and the virtual simulation signal data.

[0082] The virtual testing method of the present invention first transmits data and converts multi-source data into a unified format through control and signal acquisition equipment. The collected signal data is then preprocessed to remove noise and outliers. The noise-reduced data is then normalized, and the distances between the data points in the time series between the corresponding physical sensor signals and the virtual signals are calculated to construct a distance matrix. A dynamic programming algorithm is then used to find a path with the minimum cumulative distance in the distance matrix. Based on the optimal path, the physical signal and the virtual signal are aligned. The error between the aligned signals is then calculated as an evaluation criterion for the error between the physical and virtual signals. If the error criterion is greater than a set threshold, the parameters or structure of the digital twin model are adjusted to improve the accuracy of the virtual model. The adjusted virtual model is then re-imported into the test platform for virtual testing.

[0083] The main functions of the host computer 4 are to configure, monitor, and control the operation of the virtual test platform, analyze the collected data of the tested components or assemblies, and visualize the complete model prototype of the complex mechanism. In the present invention, after the collected data is transmitted to the host computer 4, the test collected signals are stored and visualized, and the processed data is then unpacked to the virtual vision module. The main function of the virtual test vision module is to map the motion of the actual test piece in real time on the virtual terminal, and to expand it to include, but not limited to, the corresponding spatial state of the entire landing gear mechanism. The high-performance real-time simulator reads the test piece's physical sensor signals, including but not limited to angles and linear displacements, and performs corresponding calculations. The processed signals are then transmitted to the host computer 4 in real time via the I / O interface. The host computer 4 updates the data information of the corresponding nodes of the virtual prototype based on the received physical signals, thereby driving the virtual model to update its real-time state. The monitoring system also displays key data of each node, including but not limited to angles, node forces, mechanism strains, and node coordinates. Based on the dynamic equations and simulation software, the overall spatial state information of the actual mechanism is calculated in real time and displayed in the virtual prototype.

[0084] These components work together to form a complete test platform, realizing real-time simulation, control and data acquisition of the object under test based on digital twin technology, and providing a new test platform for the verification and design of key components of complex mechanisms.

[0085] In a specific embodiment, a strut-type landing gear was used as the research object. Using this physical test platform, the strut-type landing gear prototype did not need to be fully manufactured. Instead, a digital twin model of the strut-type landing gear prototype was imported into a virtual platform for simulation. Only the physical prototype of the strut lock mechanism, the key focus, was manufactured and installed in the test platform. The hinge point connecting the strut lock mechanism and the strut lock actuator served as the top fixed end in the test. Based on the spatial kinematic relationship of the strut lock mechanism and the real-time simulation results of the complete landing gear prototype on the virtual platform, the control system manipulated the motion platform to perform the corresponding spatial kinematic relationship. Simultaneously, the servo electric cylinder 20 loaded the two hinge points connected to the test platform, simulating the load transfer of the actual strut lock mechanism. Simultaneously, based on the real-time status of the strut lock mechanism, the corresponding spatial state of the complete landing gear was updated in real time in the host computer virtual prototype.

[0086] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A virtual-reality combined test device for digital twin models, characterized by: Including test bench, drive platform, load loading module, control components and host computer; The driving platform is connected to the test bench, and a first flange block is provided on the driving platform, and the driving platform is used to drive the first flange block to move. The test bench is provided with a second flange block, and the first flange block and the second flange block are both provided with the load loading module, and the load loading module is used to apply a load to the test piece; The host computer constructs a virtual prototype model based on the digital twin; The driving platform, the load loading module and the host computer are all connected to the control component; The control component is used to run the virtual prototype model and obtain virtual simulation signal data of the nodes corresponding to the test piece, and the control component is used to control the actions of the driving platform and the load loading module according to the virtual simulation signal data.

2. The virtual-reality combined test device for digital twin models according to claim 1 is characterized in that: The control component is further used to collect physical signal data of the driving platform and the load loading module and calculate the error between the physical signal data and the virtual simulation signal data; The host computer is used to synchronously adjust the virtual prototype model in real time according to the error between the physical signal data and the virtual simulation signal data.

3. The virtual-reality combined test device for digital twin models according to claim 1 is characterized in that: The driving platform includes an X-axis driving component, a Y-axis driving component and a Z-axis driving component; The Z-direction drive assembly includes a first platform, a first screw-nut transmission assembly, a first drive device, and a first encoder. The first screw-nut transmission assembly is vertically arranged and connected to the test bench. The first drive device is used to drive the first screw-nut transmission assembly to move. One end of the first screw-nut transmission assembly is connected to the first encoder. The first platform is horizontally arranged on the first screw-nut transmission assembly. The X-axis drive assembly includes a second platform, a second screw-nut transmission assembly, a second drive device, and a second encoder. The second screw-nut transmission assembly is horizontally arranged on the first platform. The second drive device is used to drive the second screw-nut transmission assembly to move. The second encoder is provided at one end of the second screw-nut transmission assembly. The second platform is horizontally arranged on the second screw-nut transmission assembly. The Y-axis driving assembly includes a guide rail assembly, the guide rail assembly is connected to the second platform, the guide rail assembly is horizontally arranged and perpendicular to the second screw nut transmission assembly, and the first flange block is slidably connected to the guide rail assembly; An acceleration sensor is provided on the first flange block, and the acceleration sensor, the first encoder, the second encoder, the first drive device and the second drive device are all connected to the control component.

4. The virtual-reality combined test device for digital twin models according to claim 3 is characterized in that: The load loading module includes at least two mutually perpendicular loading assemblies, each of which includes a third driving device and a force sensor, the output shaft of the third driving device is connected to one end of the force sensor, and the other ends of the at least two mutually perpendicular force sensors are hinged to the end of the test piece; The force sensor and the third driving device are both connected to the control component.

5. The virtual-reality combined test device for digital twin models according to claim 4 is characterized in that: The control components include a control system, a real-time simulation system, an execution system, a signal acquisition system and a signal conditioning system; The control system is used to send a first control instruction to the real-time simulation system, and the real-time simulation system is used to run the virtual prototype model and obtain simulated load parameters and simulated motion parameters of the nodes corresponding to the test piece and feed them back to the control system; The control system is further configured to send a second control instruction to the execution system, wherein the execution system is configured to drive the load driving module to load according to the simulated load parameters and to drive the driving platform to move according to the simulated motion parameters; The signal acquisition system is used to collect physical sensor signals and send them to the real-time simulation system, and the signal conditioning system is used to process the physical sensor signals.

6. The virtual-reality combined test device for digital twin models according to claim 5 is characterized in that: The control system includes a controller, a D / A converter and a control algorithm unit; The real-time simulation system includes a real-time processor, an I / O interface board, a fault injection module and a simulation software unit, wherein the fault injection module is used to simulate a fault condition; The signal acquisition system includes a data acquisition card, a data storage module and an A / D converter, wherein the data acquisition card is used to acquire the physical sensor signal; The signal conditioning system includes an amplifier and a filter.

7. The virtual-reality combined testing device for digital twin models according to claim 3 is characterized in that: The Z-direction drive assembly includes four first screw-nut transmission assemblies, and one end of two of the first screw-nut transmission assemblies is respectively connected to the corresponding first drive device, and one end of the other two first screw-nut transmission assemblies is respectively provided with a first synchronous wheel, and the two first drive devices correspond to the two first synchronous wheels one-to-one and are connected via a belt transmission; The X-direction drive assembly includes two second screw-nut transmission assemblies, and one end of one second screw-nut transmission assembly is transmission-connected to the second drive device, and one end of the other second screw-nut transmission assembly is provided with a second synchronous wheel, and the second drive device and the second synchronous wheel are connected through a belt drive.

8. A virtual-reality combined test method for digital twin models, characterized in that: The virtual-reality combined test device for a digital twin model according to any one of claims 1 to 7 comprises the following steps: Connect the test piece to the load loading modules on the first flange block and the second flange block respectively; The control component runs the virtual prototype model and obtains virtual simulation signal data of the node corresponding to the test piece; The control component controls the driving platform to move the first flange block and controls the load loading module to load the test piece according to the virtual simulation signal data.

9. The virtual-reality combined testing method for digital twin models according to claim 8 is characterized in that: Also includes: The control component collects the physical signal data of the driving platform and the load loading module and calculates the error between the physical signal data and the virtual simulation signal data; Determining whether an error between the physical signal data and the virtual simulation signal data is greater than a threshold; If so, the host computer adjusts the virtual prototype model synchronously in real time according to the error between the physical signal data and the virtual simulation signal data.

10. The virtual-reality combined testing method for digital twin models according to claim 8, characterized in that: The step of “calculating the error between the physical signal data and the virtual simulation signal data” includes: The control component performs noise reduction processing on the collected entity signal data and performs a normalization operation on the noise-reduced data; The control component calculates the distance between the data points in the time series between the physical signal data and the virtual simulation signal data to construct a distance matrix; The control component uses a dynamic programming algorithm to find a path with the minimum cumulative distance in the distance matrix and aligns the physical signal data with the virtual simulation signal data according to the path; The control component calculates an error between the aligned physical signal data and the virtual simulation signal data.

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