An electrical control cabinet machining quality detection system based on digital twinning

Abstract

The present application relates to the field of electrical equipment intelligent manufacturing and digital twin technology, in particular to an electrical control cabinet processing quality detection system based on digital twin, comprising a data acquisition module for acquiring wire topology connection table, wire physical attribute parameters, rigid element theoretical point cloud and field measured point cloud; a space registration module for solving rigid body transformation matrix; determining virtual wire endpoint boundary conditions; an energy fitting module for constructing flexible body digital twin model; solving internal elastic potential energy and external fitting potential energy in equilibrium state; a quality judgment module for calling internal elastic potential energy, external fitting potential energy, preset distance threshold and preset deformation energy safety threshold; generating processing quality detection results; wherein the processing quality detection results include topology error, hidden damage or qualified state; the present application solves the problem that soft objects are difficult to position in rigid detection, and fills the gap that existing technology cannot perceive internal mechanical hidden dangers.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing and digital twin technology for electrical equipment, specifically to a processing quality inspection system for electrical control cabinets based on digital twins. Background Technology

[0002] Electrical control cabinet manufacturing is a core component of industrial automation equipment production, involving the complex layout and precise connection of numerous wires within a limited space. Current quality inspection methods typically employ automated optical inspection, capturing images of the wires' appearance to identify connection defects. Wires are flexible materials, naturally sag under gravity in real-world environments, and their shape is influenced by physical properties such as Young's modulus and moment of inertia. Existing technologies, relying primarily on geometric vision, struggle to distinguish between normal gravitational sag and substantial wiring errors, limiting inspection accuracy. Furthermore, traditional vision techniques can only observe the external morphology of wires, failing to perceive their internal mechanical state. Existing technologies cannot effectively identify hidden damage caused by excessive elastic potential energy accumulation due to excessively short cutting lengths or small local bending radii, even when visually the connection position is correct. Such internal stress hazards can easily lead to loose terminals or wire breakage after prolonged operation. Therefore, a solution is urgently needed to address the current limitations in distinguishing between gravitational influences and wiring errors, as well as the inability to identify internal stress hazards in wires. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a digital twin-based electrical control cabinet manufacturing quality inspection system. Specifically, the technical solution of this invention includes:

[0004] The data acquisition module is used to acquire conductor topology connection tables, conductor physical property parameters, theoretical point clouds of rigid elements, and field measured point clouds;

[0005] The spatial registration module is used to call up the theoretical point cloud and the measured point cloud of the rigid element; solve the rigid body transformation matrix; and determine the boundary conditions of the virtual traverse endpoints based on the rigid body transformation matrix.

[0006] The energy fitting module is used to construct a digital twin model of a flexible body; it performs inverse fitting of the digital twin model of the flexible body to the measured point cloud on site based on the principle of energy minimization; and it calculates the internal elastic potential energy and the external fitting potential energy under equilibrium state.

[0007] The quality judgment module is used to call the internal elastic potential energy, external fitting potential energy, preset distance threshold, and preset deformation energy safety threshold; based on the internal elastic potential energy, external fitting potential energy, distance threshold, and deformation energy safety threshold, it generates processing quality inspection results;

[0008] The processing quality inspection results include topological errors, hidden damage, or qualified status.

[0009] Preferably, the physical property parameters of the conductor include:

[0010] Young's modulus is used to characterize the ability of a conductor to resist tensile deformation.

[0011] Moment of inertia of a cross section is used to characterize the ability of a conductor to resist bending deformation;

[0012] Linear density, used to calculate gravitational potential energy;

[0013] Virtual coupling stiffness, used for fitting calculations.

[0014] Preferably, the spatial registration module calculates the rigid body transformation matrix based on the theoretical point cloud of the rigid element and the measured point cloud in the field, and determines the boundary conditions of the virtual traverse endpoints based on the rigid body transformation matrix, including:

[0015] Call upon theoretical point clouds and field measured point clouds of rigid components;

[0016] The iterative nearest point algorithm is used to calculate the rotation matrix and translation vector by minimizing the Euclidean distance;

[0017] Apply the rotation matrix and translation vector to the endpoints of the virtual conductor;

[0018] Transform the virtual conductor endpoints to the sensor coordinate system to generate virtual conductor endpoint boundary conditions.

[0019] Preferably, the energy fitting module calculates the internal elastic potential energy in equilibrium, including:

[0020] Discretize the flexible body digital twin model into a point mass system;

[0021] Based on the discrete elastic rod model, the elastic potential energy generated by the stretching of the particle system is calculated.

[0022] Based on the discrete elastic rod model, the elastic potential energy of a particle system due to bending is calculated.

[0023] The internal elastic potential energy is generated by summing the elastic potential energy generated by stretching and the elastic potential energy generated by bending.

[0024] Preferably, the energy fitting module calculates the external fitting potential energy in the equilibrium state, including:

[0025] Determine the nearest neighbor point in the on-site measured point cloud that is the node of the flexible body digital twin model;

[0026] Calculate the Euclidean distance between a node and its nearest neighbor;

[0027] Call the virtual coupling stiffness from the physical property parameters of the conductor;

[0028] Based on Euclidean distance and virtual coupling stiffness, the virtual potential field is calculated using the penalty function method to generate the external fitting potential energy.

[0029] Preferably, the process for generating the deformation energy safety threshold used in the quality decision module includes:

[0030] Obtain the theoretical total length of the conductor and the moment of inertia of its cross section;

[0031] Call the preset engineering tolerance coefficient and Young's modulus;

[0032] Based on the bending energy theory of beams, a deformation energy safety threshold is generated by calculating the engineering tolerance coefficient, Young's modulus, moment of inertia of the section, and the total theoretical length of the conductor.

[0033] Preferably, the quality judgment module generates processing quality inspection results that include topology errors, including:

[0034] Compare the external fitting potential with a distance threshold;

[0035] When the external fitting potential energy exceeds the distance threshold, it is determined that the flexible body digital twin model cannot be matched to the actual measured point cloud position.

[0036] Generate a topology error that represents a wiring path error.

[0037] Preferably, the quality judgment module generates processing quality inspection results that include latent damage, including:

[0038] Compare the external fitting potential with a distance threshold;

[0039] Compare the internal elastic potential energy with the deformation energy safety threshold;

[0040] In response to the external fitting potential energy being less than or equal to the distance threshold and the internal elastic potential energy being greater than the deformation energy safety threshold, it is determined that excessive elastic potential energy has accumulated inside the conductor.

[0041] Generate latent damage that indicates excessive stress on the conductor or excessive bending of the wiring.

[0042] Preferably, the quality judgment module generates processing quality inspection results including a pass / fail status, including:

[0043] Compare the external fitting potential with a distance threshold;

[0044] Compare the internal elastic potential energy with the deformation energy safety threshold;

[0045] If the external fitting potential energy is less than or equal to the distance threshold and the internal elastic potential energy is less than or equal to the deformation energy safety threshold, it is determined that the wire connection position is correct and the internal stress is within the safe range.

[0046] Generate a qualified status.

[0047] Compared with the prior art, the present invention has the following beneficial effects:

[0048] 1. By introducing physical property parameters such as linear density and cross-sectional moment of inertia into the flexible body digital twin model, this system can realistically simulate the natural sag of the conductor under gravity. This enables the detection system to have physical perception capabilities, effectively overcoming the shortcomings of traditional automatic optical detection that relies solely on geometric visual information and is unable to distinguish between normal gravity sag of the conductor and substantial wiring errors. This significantly improves the accuracy of conductor topology path identification in complex spatial layouts.

[0049] 2. This system achieves quantitative analysis of stress state by calculating the internal elastic potential energy of the conductor in equilibrium state. Even if the conductor is visually correctly connected, the system can detect hidden damage such as forced straightening or local excessive bending caused by excessively short cutting by comparing the internal potential energy with the deformation energy safety threshold. This effectively avoids the risk of terminal loosening or breakage after long-term operation caused by excessive internal stress accumulation, and fills the gap in existing technology that cannot detect internal mechanical hazards.

[0050] 3. This system utilizes the principle of energy minimization and the virtual coupling stiffness algorithm to establish a balance mechanism between internal elastic force and external fitting force; it uses the penalty function method to accurately converge the flexible body model to the measured point cloud on site, solving the problem of difficulty in locating soft objects in rigidity detection; this inverse fitting based on physical laws not only ensures the high consistency between the virtual model and the real object in geometric position, but also ensures that the fitted mechanical parameters can truly reflect the physical state of the on-site conductor.

[0051] 4. This system constructs a dual threshold decision logic based on external fitting potential energy and internal elastic potential energy, realizing a comprehensive evaluation of processing quality from two dimensions: geometric consistency and mechanical safety. The system can automatically generate classification detection results including topological errors, hidden damage, and qualified status, transforming fuzzy quality assessments into quantifiable physical indicators, ensuring that the final delivered electrical control cabinet not only meets wiring process specifications but also satisfies the mechanical safety requirements for long-term operation. Attached Figure Description

[0052] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0053] Figure 1 This is a structural diagram of the system of the present invention. Detailed Implementation

[0054] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0055] Example 1:

[0056] Please see Figure 1 A digital twin-based electrical control cabinet manufacturing quality inspection system includes:

[0057] The data acquisition module is used to acquire conductor topology connection tables, conductor physical property parameters, theoretical point clouds of rigid elements, and field measured point clouds;

[0058] The spatial registration module is used to call up the theoretical point cloud and the measured point cloud of the rigid element; solve the rigid body transformation matrix; and determine the boundary conditions of the virtual traverse endpoints based on the rigid body transformation matrix.

[0059] The energy fitting module is used to construct a digital twin model of a flexible body; it performs inverse fitting of the digital twin model of the flexible body to the measured point cloud on site based on the principle of energy minimization; and it calculates the internal elastic potential energy and the external fitting potential energy under equilibrium state.

[0060] The quality judgment module is used to call the internal elastic potential energy, external fitting potential energy, preset distance threshold, and preset deformation energy safety threshold; based on the internal elastic potential energy, external fitting potential energy, distance threshold, and deformation energy safety threshold, it generates processing quality inspection results;

[0061] The processing quality inspection results include topological errors, hidden damage, or qualified status.

[0062] This embodiment provides a digital twin-based electrical control cabinet manufacturing quality inspection system. The system aims to solve the technical problems of existing automatic optical inspection technology, which is unable to distinguish between wire sag due to gravity and wiring errors, and cannot identify potential internal stress problems in wires. The system mainly includes a data acquisition module, a spatial registration module, an energy fitting module, and a quality judgment module.

[0063] The data acquisition module is used to obtain all the basic data required to build the digital twin model. Specifically, the data acquired by this module includes conductor topology connection tables, conductor physical property parameters, theoretical point clouds of rigid components, and field-measured point clouds. Among them, the conductor topology connection tables are derived from netlists generated from electrical auxiliary design software or electrical schematic diagrams, and contain the starting coordinates of each conductor. Termination coordinates and theoretical length Theoretical point cloud of rigid elements It consists of geometric point cloud data of terminal blocks, circuit breakers, and cable trays derived from computer-aided design models; and field-measured point cloud data. These are point cloud data containing spatial depth information collected at the electrical control cabinet processing site using a 3D depth camera or lidar.

[0064] The spatial registration module is used to establish the mapping relationship between virtual space and physical space. This module calls the theoretical point cloud of rigid element and the measured point cloud on site, and solves the rigid body transformation matrix through rigid body transformation algorithm. Based on the solved rigid body transformation matrix, this module determines the boundary conditions of the virtual conductor endpoints. That is, through coordinate transformation, the theoretical starting coordinates and ending coordinates of the virtual conductor are accurately mapped to the coordinate system of the field sensor, thereby providing accurate geometric constraint anchor points for subsequent flexible body simulation.

[0065] The energy fitting module is used to reconstruct the true shape of the conductor under the constraints of physical laws. This module constructs a flexible digital twin model containing mechanical properties and performs inverse fitting of the flexible digital twin model to the measured point cloud on site based on the principle of energy minimization. In this process, the module finds the equilibrium state that minimizes the total energy of the system through iterative calculation and solves the internal elastic potential energy and external fitting potential energy under the equilibrium state.

[0066] The quality judgment module is used to achieve quantitative quality assessment. This module calls the internal elastic potential energy and external fitted potential energy calculated by the energy fitting module, and performs logical judgment in combination with the preset distance threshold and the preset deformation energy safety threshold. Based on the comprehensive comparison of internal elastic potential energy, external fitted potential energy, distance threshold and deformation energy safety threshold, this module generates processing quality inspection results. The processing quality inspection results specifically include topological errors that indicate incorrect wiring paths, hidden damage that indicates excessive stress or excessive bending of wiring, and qualified status that indicates correct connection and stress safety.

[0067] Example 2:

[0068] The physical properties of the conductor include:

[0069] Young's modulus is used to characterize the ability of a conductor to resist tensile deformation.

[0070] Moment of inertia of a cross section is used to characterize the ability of a conductor to resist bending deformation;

[0071] Linear density, used to calculate gravitational potential energy;

[0072] Virtual coupling stiffness, used for fitting calculations.

[0073] This embodiment defines and limits the physical property parameters of the conductor to ensure that the digital twin model has a realistic mechanical response capability. The physical property parameters of the conductor are derived from the cable specification or material mechanical test data, specifically including Young's modulus, moment of inertia of section, linear density and virtual coupling stiffness.

[0074] Young's modulus The moment of inertia is used to characterize the resistance of a conductor to tensile deformation; its unit is Pascal, and its value depends on the composite material properties of the conductor's metallic core and insulation layer. Linear density is used to characterize a conductor's resistance to bending deformation; its unit is 4th power meters, and this parameter is determined by the conductor's cross-sectional geometry and dimensions. Used to calculate gravitational potential energy, measured in kilograms per meter. This parameter allows the model to simulate the natural sag of a conductor under gravity, thus avoiding misjudging normal gravitational sag as a defect; virtual coupling stiffness. Used for fitting calculations, its unit is Newtons per meter; in this embodiment, the virtual coupling stiffness is not an inherent property of the conductor itself, but an algorithm parameter related to the accuracy of the measuring equipment; its value is related to the measurement uncertainty of the sensor. Inversely proportional, that is, the higher the sensor accuracy, the larger the virtual coupling stiffness setting value. Specifically, virtual coupling stiffness... The calculation formula is:

[0075] ;

[0076] in, The Young's modulus of the conductor. The cross-sectional area of ​​the conductor is... The standard deviation of the measuring equipment is used as the characteristic length, in meters; in the formula Located to the first power of the denominator to ensure the calculated stiffness The unit is Newtons per meter, which conforms to the dimensional requirements of Hooke's law for linear elasticity. This is a dimensionless equilibrium coefficient, with a value range of [value missing]. to This coefficient is used to balance the internal elastic force and the external fitting force, preventing simulation numerical oscillations caused by excessive stiffness or fitting failure caused by insufficient stiffness; thus making the model more inclined to closely fit the measured point cloud.

[0077] Example 3:

[0078] The spatial registration module calculates the rigid body transformation matrix based on the theoretical point cloud of rigid elements and the measured point cloud in the field, and determines the boundary conditions of the virtual traverse endpoints based on the rigid body transformation matrix, including:

[0079] Call upon theoretical point clouds and field measured point clouds of rigid components;

[0080] The iterative nearest point algorithm is used to calculate the rotation matrix and translation vector by minimizing the Euclidean distance;

[0081] Apply the rotation matrix and translation vector to the endpoints of the virtual conductor;

[0082] Transform the virtual conductor endpoints to the sensor coordinate system to generate virtual conductor endpoint boundary conditions.

[0083] This embodiment details the specific logic of the spatial registration module performing rigid registration; the spatial registration module is based on the point cloud of rigid element theory. and on-site measured point cloud Solve the rigid body transformation matrix and determine the boundary conditions of the virtual conductor endpoints based on the rigid body transformation matrix;

[0084] This process invokes the point cloud theory of rigid elements. and on-site measured point cloud A variant of the iterative nearest-point algorithm is used to calculate the rotation matrix by minimizing the Euclidean distance. and translation vector The specific optimization objective function is expressed as finding the sum of squared distances between the transformed theoretical point cloud and the measured point cloud. and The calculation formula is as follows:

[0085] ;

[0086] in, This indicates the number of point pairs involved in the calculation. Point cloud for rigid element theory The first in One point, For on-site measured point cloud The corresponding nearest neighbor point, For rotation matrix, It is a translation vector;

[0087] To obtain the optimal rotation matrix and translation vector Then, the spatial registration module applies the rotation matrix and translation vector to the endpoints of the virtual traverse; that is, it applies the theoretical starting coordinates defined in the traverse topology connection table. and termination coordinates A rigid body transformation is performed to convert the virtual wire endpoints to the sensor coordinate system, generating virtual wire endpoint boundary conditions. This ensures that both ends of the virtual wire are fixed in the accurate position of the terminal block in the real world, eliminating the detection reference deviation caused by tooling positioning error.

[0088] Example 4:

[0089] The energy fitting module calculates the internal elastic potential energy in equilibrium, including:

[0090] Discretize the flexible body digital twin model into a point mass system;

[0091] Based on the discrete elastic rod model, the elastic potential energy generated by the stretching of the particle system is calculated.

[0092] Based on the discrete elastic rod model, the elastic potential energy of a particle system due to bending is calculated.

[0093] The internal elastic potential energy is generated by summing the elastic potential energy generated by stretching and the elastic potential energy generated by bending.

[0094] This embodiment details the specific method for calculating the internal elastic potential energy using the energy fitting module. Internal elastic potential energy is a key indicator for evaluating the internal stress state of a conductor. The process by which the energy fitting module calculates the internal elastic potential energy under equilibrium conditions is as follows:

[0095] Before discretization, an initialization step is performed: based on the virtual traverse endpoint boundary conditions determined by the spatial registration module, i.e., the transformed starting coordinates. and termination coordinates In three-dimensional space, an initial straight-line path or an initial curved path based on the catenary equation connecting the two points is generated as the zero-time state of the flexible body digital twin model; the flexible body digital twin model is discretized into a particle system; this particle system contains There are discrete nodes, and their position vectors are represented as follows: The connection vector between adjacent nodes is represented as ;

[0096] Based on the discrete elastic rod model, the elastic potential energy generated by tension and the elastic potential energy generated by bending of the particle system are calculated respectively.

[0097] The internal elastic potential energy is generated by summing the elastic potential energy generated by stretching and the elastic potential energy generated by bending. In this embodiment, the formula for calculating the internal elastic potential energy is as follows:

[0098] ;

[0099] in, This represents the internal elastic potential energy, measured in joules. For Young's modulus, The cross-sectional area of ​​the conductor is... The moment of inertia of the cross section; For the first The natural original length of a conductor segment. This is the actual length of the conductor unit after deformation; the difference between the two reflects the tensile deformation. For two adjacent vectors and The angle between them, i.e., the curvature angle, is used to characterize the local curvature; this curvature angle Accurate calculation using the vector dot product formula:

[0100] ;

[0101] In addition, to prevent division by zero errors, when When the node is determined to be in a degenerate state, a bending angle is forcibly set. The value is 0, and the calculation of bending energy for that node is skipped; through this formula, the system can accurately quantify the physical energy stored inside the conductor due to stretching and bending.

[0102] Example 5:

[0103] The energy fitting module calculates the external fitted potential energy at equilibrium, including:

[0104] Determine the nearest neighbor point in the on-site measured point cloud that is the node of the flexible body digital twin model;

[0105] Calculate the Euclidean distance between a node and its nearest neighbor;

[0106] Call the virtual coupling stiffness from the physical property parameters of the conductor;

[0107] Based on Euclidean distance and virtual coupling stiffness, the virtual potential field is calculated using the penalty function method to generate the external fitting potential energy.

[0108] To achieve the aforementioned energy minimization solution, the energy fitting module employs a projection dynamics algorithm for iterative calculation; specifically, the system solves the following linear system to update the node positions. :

[0109] ;

[0110] in, The node quality matrix, Let Laplace's matrix correspond to the internal elastic potential energy and the external fitted potential energy. The time step is fixed, ranging from 0.01s to 0.03s. To select a matrix, This is a local projection operator that projects the current state onto the constrained manifold; where matrix J is chosen as a diagonal matrix to identify fixed-point constraints, and for endpoints determined by boundary conditions, their corresponding diagonal elements are set to 1, and the rest to 0; this iterative process continues until the rate of change of the total energy of the system is reached. Once the Joule count reaches the maximum number of iterations (50), the system is considered to have reached equilibrium.

[0111] Specifically, matrix The construction method is as follows: for each discrete traverse element, calculate its second derivative with respect to the position variable, and assemble the local matrices of all elements to generate a global sparse matrix, which represents the overall topology and stiffness characteristics of the system.

[0112] Local projection operator The computational logic is as follows: the system is decomposed into independent local constraint subproblems, including constraints for maintaining element length and constraints for maintaining bending angle. For each subproblem, ignoring other constraints, the system calculates the nearest geometric position that satisfies the constraint condition when moving the current node position, thereby obtaining the local target position projection. This step solves the problem of linearizing the solution of nonlinear constraints.

[0113] This embodiment details the specific method for the energy fitting module to calculate the external fitting potential energy; the external fitting potential energy is used to quantify the geometric consistency between the virtual model and the measured data; the process by which the energy fitting module solves for the external fitting potential energy in the equilibrium state is as follows:

[0114] Determine the on-site measured point cloud In the flexible body digital twin model node nearest neighbor ;

[0115] compute nodes Its nearest neighbor in the measured point cloud The Euclidean distance between them;

[0116] Call the virtual coupling stiffness in the physical property parameters of the conductor ;

[0117] Based on Euclidean distance and virtual coupling stiffness, the virtual potential field is calculated using the penalty function method to generate the external fitting potential energy. In this embodiment, the formula for calculating the external fitting potential energy is as follows:

[0118] ;

[0119] in, This represents the external fitting potential energy, expressed in joules. This represents the total number of nodes in the flexible body model. For virtual coupling stiffness; Represents model nodes To the measured point cloud The square of the shortest distance; this energy term is physically equivalent to applying a stiffness of between the virtual conductor and the measured point cloud. The virtual spring forces the virtual conductor to move closer to the measured data during the simulation process.

[0120] Example 6:

[0121] The process for generating the deformation energy safety threshold used in the quality decision module includes:

[0122] Obtain the theoretical total length of the conductor and the moment of inertia of its cross section;

[0123] Call the preset engineering tolerance coefficient and Young's modulus;

[0124] Based on the bending energy theory of beams, a deformation energy safety threshold is generated by calculating the engineering tolerance coefficient, Young's modulus, moment of inertia of the section, and the total theoretical length of the conductor.

[0125] This embodiment details the process of generating the deformation energy safety threshold. This threshold is not a fixed empirical value, but a physical quantity dynamically calculated based on the geometric characteristics of each conductor, used to determine whether the internal stress of the conductor exceeds the limit. The generation process of the deformation energy safety threshold used in the quality judgment module is as follows:

[0126] Obtain the theoretical total length of the current conductor to be tested. and moment of inertia of cross section ;

[0127] Call the preset engineering tolerance coefficient and Young's modulus Among them, the engineering tolerance coefficient It is a dimensionless constant, set according to the process quality specifications of the electrical control cabinet, for example, taking the value of... to Between these values, the allowable range of energy redundancy is defined;

[0128] Based on the bending energy theory of beams, a safe threshold for deformation energy is generated through calculations using engineering tolerance coefficients, Young's modulus, moment of inertia of the section, and the total theoretical length of the conductor. The calculation formula is as follows:

[0129] ;

[0130] in, This represents the safety threshold for deformation energy, measured in joules; the formula reflects the laws of physics, namely, the bending stiffness... Under certain conditions, the longer the conductor, the better its flexibility, and the lower the energy density required to accommodate the same bend. Therefore, the theoretical total length is... Located in the denominator; this threshold characterizes the maximum elastic potential energy that a conductor of a specific length can store without plastic deformation or excessive stress on the terminals; in this formula, the theoretical total length Located in the denominator, it is based on the influence of the slenderness ratio on stability. Physically, the longer the conductor, the greater its structural flexibility, and it is easier to generate large-scale low-energy mode bending under the same process disturbance. Therefore, the system needs to set more stringent requirements for long conductors, that is, a lower unit energy density threshold, in order to eliminate those long-line short-circuit type process defects that are not broken but have too loose or redundant shapes.

[0131] Example 7:

[0132] The quality judgment module generates processing quality inspection results that include topology errors, including:

[0133] Compare the external fitting potential with a distance threshold;

[0134] When the external fitting potential energy exceeds the distance threshold, it is determined that the flexible body digital twin model cannot be matched to the actual measured point cloud position.

[0135] Generate a topology error that represents a wiring path error.

[0136] This embodiment details how the system identifies topology errors; topology errors typically correspond to situations such as completely incorrect wiring positions, missing wires, or severely deviated paths; the process by which the quality judgment module generates processing quality inspection results that include topology errors is as follows:

[0137] The external fitting potential energy obtained after energy fitting optimization Distance threshold Comparison; Distance threshold This energy value is set based on the accuracy of the point cloud acquisition equipment and the allowable wiring space error. For example, when the allowable average distance deviation is... At that time, the distance threshold can be set to ;

[0138] In response to the external fitting potential energy being greater than the distance threshold, i.e. The system determines that the flexible digital twin model cannot be matched to the actual measured point cloud location. Physically, this means that no matter how the virtual wire is deformed, it cannot be pulled to the location of the measured point cloud, indicating that the physical entity is not near the path specified in the schematic diagram. Based on this, the module generates a topology error that represents the wiring path error.

[0139] Example 8:

[0140] The quality judgment module generates processing quality inspection results that include latent defects, including:

[0141] Compare the external fitting potential with a distance threshold;

[0142] Compare the internal elastic potential energy with the deformation energy safety threshold;

[0143] In response to the external fitting potential energy being less than or equal to the distance threshold and the internal elastic potential energy being greater than the deformation energy safety threshold, it is determined that excessive elastic potential energy has accumulated inside the conductor.

[0144] Generate latent damage that indicates excessive stress on the conductor or excessive bending of the wiring.

[0145] This embodiment details how the system identifies latent damage; this is one of the core advantages of the invention, capable of detecting visually correct but excessively stressed defects that cannot be identified by traditional vision technology; the process by which the quality judgment module generates processing quality inspection results containing latent damage is as follows:

[0146] External fitting potential energy With distance threshold Comparison, while simultaneously considering internal elastic potential energy With deformation energy safety threshold Compare;

[0147] The condition is met when the external fitted potential energy is less than or equal to the distance threshold and the internal elastic potential energy is greater than the deformation energy safety threshold. and When the condition is met, the system determines that excessive elastic potential energy has accumulated inside the conductor. At this time, although the conductor is geometrically aligned with the terminal connection, i.e., the fitting residual is small, the model has undergone excessive stretching or severe bending in order to reach this position. This situation corresponds to the situation in real-world scenarios where the conductor is forcibly straightened due to being cut too short, or the local curvature radius of the wiring is too small, i.e., excessive bending. Based on this, the module generates a hidden damage characterizing excessive force on the conductor or excessive bending of the wiring, indicating the risk of terminal loosening or long-term breakage.

[0148] Example 9:

[0149] The quality judgment module generates processing quality inspection results that include a pass / fail status, including:

[0150] Compare the external fitting potential with a distance threshold;

[0151] Compare the internal elastic potential energy with the deformation energy safety threshold;

[0152] If the external fitting potential energy is less than or equal to the distance threshold and the internal elastic potential energy is less than or equal to the deformation energy safety threshold, it is determined that the wire connection position is correct and the internal stress is within the safe range.

[0153] Generate a qualified status.

[0154] This embodiment details the logic of the system in determining the pass / fail status; only when the geometric position and physical state of the conductor meet the requirements is it considered pass / fail; the process by which the quality judgment module generates processing quality inspection results containing the pass / fail status is as follows:

[0155] External fitting potential energy With distance threshold Compare and use internal elastic potential energy With deformation energy safety threshold Compare;

[0156] The condition is met when the external fitted potential energy is less than or equal to the distance threshold and the internal elastic potential energy is less than or equal to the deformation energy safety threshold. and When the conditions are met, the system determines that the wire connection position is correct and the internal stress is within a safe range; accordingly, the module generates a qualified status, indicating that the wire processing quality meets the design requirements and long-term operation safety standards.

[0157] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A digital twin-based electrical control cabinet manufacturing quality inspection system, characterized in that, include: The data acquisition module is used to acquire conductor topology connection tables, conductor physical property parameters, theoretical point clouds of rigid elements, and field measured point clouds; The spatial registration module is used to call up the theoretical point cloud and the measured point cloud of the rigid element; solve the rigid body transformation matrix; and determine the boundary conditions of the virtual traverse endpoints based on the rigid body transformation matrix. The energy fitting module is used to construct a digital twin model of a flexible body; it performs inverse fitting of the digital twin model of the flexible body to the measured point cloud on site based on the principle of energy minimization; and it calculates the internal elastic potential energy and the external fitting potential energy under equilibrium state. The quality judgment module is used to call the internal elastic potential energy, the external fitting potential energy, the preset distance threshold, and the preset deformation energy safety threshold. Based on the internal elastic potential energy, external fitting potential energy, distance threshold, and deformation energy safety threshold, the processing quality inspection results are generated. The processing quality inspection results include topological errors, hidden damage, or qualified status; The quality judgment module generates processing quality inspection results that include topology errors, including: Compare the external fitting potential with a distance threshold; When the external fitting potential energy exceeds the distance threshold, it is determined that the flexible body digital twin model cannot be matched to the actual measured point cloud position. Generate a topology error that represents a wiring path error; The quality judgment module generates processing quality inspection results that include latent defects, including: Compare the external fitting potential with a distance threshold; Compare the internal elastic potential energy with the deformation energy safety threshold; In response to the external fitting potential energy being less than or equal to the distance threshold and the internal elastic potential energy being greater than the deformation energy safety threshold, it is determined that excessive elastic potential energy has accumulated inside the conductor. Generate latent damage that characterizes excessive stress on the conductor or excessive bending of the wiring; The quality judgment module generates processing quality inspection results that include a pass / fail status, including: Compare the external fitting potential with a distance threshold; Compare the internal elastic potential energy with the deformation energy safety threshold; If the external fitting potential energy is less than or equal to the distance threshold and the internal elastic potential energy is less than or equal to the deformation energy safety threshold, it is determined that the wire connection position is correct and the internal stress is within the safe range. Generate a qualified status.

2. The electrical control cabinet processing quality inspection system based on digital twin as described in claim 1, characterized in that, The physical properties of the conductor include: Young's modulus is used to characterize the ability of a conductor to resist tensile deformation. Moment of inertia of a cross section is used to characterize the ability of a conductor to resist bending deformation; Linear density, used to calculate gravitational potential energy; Virtual coupling stiffness, used for fitting calculations.

3. The electrical control cabinet processing quality inspection system based on digital twin as described in claim 1, characterized in that, The spatial registration module calculates the rigid body transformation matrix based on the theoretical point cloud of rigid elements and the measured point cloud in the field, and determines the boundary conditions of the virtual traverse endpoints based on the rigid body transformation matrix, including: Call upon theoretical point clouds and field measured point clouds of rigid components; The iterative nearest point algorithm is used to calculate the rotation matrix and translation vector by minimizing the Euclidean distance; Apply the rotation matrix and translation vector to the endpoints of the virtual conductor; Transform the virtual conductor endpoints to the sensor coordinate system to generate virtual conductor endpoint boundary conditions.

4. The electrical control cabinet processing quality inspection system based on digital twin as described in claim 1, characterized in that, The energy fitting module calculates the internal elastic potential energy in equilibrium, including: Discretize the flexible body digital twin model into a point mass system; Based on the discrete elastic rod model, the elastic potential energy generated by the stretching of the particle system is calculated. Based on the discrete elastic rod model, the elastic potential energy of a particle system due to bending is calculated. The internal elastic potential energy is generated by summing the elastic potential energy generated by stretching and the elastic potential energy generated by bending.

5. The electrical control cabinet processing quality inspection system based on digital twin according to claim 1, characterized in that, The energy fitting module calculates the external fitted potential energy at equilibrium, including: Determine the nearest neighbor point in the on-site measured point cloud that is the node of the flexible body digital twin model; Calculate the Euclidean distance between a node and its nearest neighbor; Call the virtual coupling stiffness from the physical property parameters of the conductor; Based on Euclidean distance and virtual coupling stiffness, the virtual potential field is calculated using the penalty function method to generate the external fitting potential energy.

6. The electrical control cabinet processing quality inspection system based on digital twin according to claim 1, characterized in that, The process for generating the deformation energy safety threshold used in the quality decision module includes: Obtain the theoretical total length of the conductor and the moment of inertia of its cross section; Call the preset engineering tolerance coefficient and Young's modulus; Based on the bending energy theory of beams, a deformation energy safety threshold is generated by calculating the engineering tolerance coefficient, Young's modulus, moment of inertia of the section, and the total theoretical length of the conductor.

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