A general method for constructing a complex equipment digital twin platform

Abstract

The application discloses a general method for constructing a digital twin of complex equipment, real-time acquisition of physical prototype posture data, hydraulic system parameters, controller internal parameters and other data is realized through high-performance sensors, and data is automatically processed through a 4G network and a data transmission link to realize real-time return of the data to a cloud database. Real-time acquisition of field data as a database basic data layer, data classification and feature recognition of the basic data are used for model simulation and performance model calculation, and posture reproduction of the equipment, system parameter identification, optimization strategy feedback, operation performance evaluation and simulation verification are realized, and finally, simulation verification results and performance evaluation results are output in front end. The digital twin technology is applied to real-time monitoring of the states of main systems of complex equipment, performance of the main systems of the complex equipment is evaluated in time according to the monitoring results, and this is helpful to reduce the failure probability of the main systems, and is of great significance for optimization and health monitoring of the whole machine.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of complex equipment digital twinning, in particular to a general method for constructing a complex equipment digital twinning platform. BACKGROUND

[0002] In recent years, with the development of sensor technology, communication network technology and computer technology, digital twinning technology has developed rapidly. At present, digital twinning technology is relatively mature in the field of aerospace, but its application in the field of engineering machinery is still in the exploratory stage.

[0003] In the field of infrastructure, various modern complex equipment is widely used. Due to the complex and harsh construction environment of engineering complex equipment and the existence of large load impact in the construction process, the main system may fail.

[0004] However, the existing digital twinning platform of complex equipment mostly only focuses on the fatigue failure of the mechanical structure or key mechanical parts of the equipment, and lacks a mature platform that can monitor system-level failures. SUMMARY

[0005] Therefore, the present application provides a general method for constructing a complex equipment digital twinning platform, which can realize real-time state monitoring and performance evaluation of complex equipment, and to a certain extent, realize health monitoring of the main system of complex equipment.

[0006] To this end, the present application provides the following technical solutions:

[0007] The present application provides a general method for constructing a complex equipment digital twinning platform, comprising:

[0008] The data system realizes real-time collection of physical prototype attitude data, hydraulic system parameters and controller internal parameters through high-performance sensors, and returns the data to the cloud database in real time; the real-time acquired field data is used as the basic data of the data system, and the basic data is classified and feature-recognized;

[0009] The model system uses a universal simulation software to build high-fidelity models of various hydraulic elements and mechanical elements in the complex equipment, and performs secondary development on the mechanical model of the equipment to realize three-dimensional to one-dimensional reduction processing, combines the built element models into a system circuit and performs parameter setting;

[0010] The application system develops a performance evaluation model through Python, develops a fault diagnosis and prediction algorithm for critical components, and performs performance evaluation calculation on the simulation results of the model system based on the data classification and feature recognition results obtained by the data system, to realize attitude reproduction, system parameter identification, simulation verification, running state monitoring and performance evaluation of the equipment;

[0011] The interactive system establishes a data channel between a simulation model, an instrument display interface and a three-dimensional visualization software, so that the data in the digital twin model can be dynamically displayed on the basis of the three-dimensional model of the complex equipment; and the device state is output in real time based on the real-time simulation result.

[0012] Further, the data is real-time returned to the cloud database, including:

[0013] The data is real-time returned to the cloud database through a 4G network and a data transmission link.

[0014] Further, in the data system, the data in the database is stored and read by using an SQL statement, transmitted to an application system for performance evaluation analysis by using an Http protocol, and transmitted to a model system and an interactive system for simulation calculation and animation display.

[0015] Further, the model system uses a universal simulation software to build a model of the complex equipment, and integrates a mechanical system and a hydraulic system.

[0016] Further, the model system simplifies the moment of inertia of the upper car mechanism in the three-dimensional model; and a function of the total moment of inertia and the swing angle of the boom is fitted by using a data analysis software.

[0017] Further, the application system uses an Http protocol to realize data interaction, and transmits the data returned by the performance evaluation model to the interactive system.

[0018] Further, the interactive system is also used for realizing state monitoring of each element of the complex equipment and data information management under the driving of the data system and the support of the model system.

[0019] Further, the interactive system provides real-time monitoring and reliable operation and maintenance services.

[0020] The application has the advantages that the universal method provided by the application for constructing a digital twin platform of complex equipment can ensure continuous and stable construction of the equipment, and can build a high-fidelity and low-latency automatic monitoring platform by using a digital twin technology to realize real-time monitoring of the main system of the complex equipment and timely evaluation of the performance, so as to help reduce the failure probability of the main system of the complex equipment, reduce the downtime maintenance time, greatly improve the construction efficiency, and have important significance for optimization and health monitoring of the whole machine. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings described below are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor based on these drawings.

[0022] Figure 1 is a flow diagram of the general construction method of the digital twin platform of the rotary system in the embodiments of the present application;

[0023] Figure 2 is a data flow diagram in the embodiments of the present application;

[0024] Figure 3 is a simulation model diagram of the rotary system in the embodiments of the present application;

[0025] Figure 4 is a man-machine interaction home page interface diagram of the digital twin platform in the embodiments of the present application;

[0026] Figure 5 is a fault display interface diagram of the digital twin platform in the embodiments of the present application;

[0027] Figure 6 is a dial display interface diagram of the digital twin platform in the embodiments of the present application;

[0028] Figure 7 is a trend curve interface diagram of the digital twin platform in the embodiments of the present application;

[0029] Figure 8 is a complex equipment pose display interface diagram of the digital twin platform in the embodiments of the present application. DETAILED DESCRIPTION

[0030] In order to make the person skilled in the art better understand the present application, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor should belong to the scope of protection of the present application.

[0031] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and in the above drawings are used to distinguish similar objects, and do not necessarily have to be used to describe a specific order or sequence. It should be understood that the data thus used can be interchanged under appropriate circumstances, so that the embodiments of the application described herein can be implemented in an order other than that illustrated or described herein. In addition, the terms "include" and "have" and any variations thereof are intended to cover non-exclusive inclusion, for example, a process, method, system, product or device that includes a series of steps or units does not have to be limited to only those steps or units clearly listed, but can include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0032] Complex equipment refers to a type of product with complex customer demand, complex system composition, complex product technology, complex manufacturing process, complex test and maintenance, complex project management and complex working environment, and the development cycle is relatively long and generally adopts single-piece and small-batch production mode. In the embodiments of the present application, the complex equipment such as the slewing system is taken as an example to explain the general construction method of the digital twin platform of the complex equipment proposed in the present application. The slewing system mainly includes: a loading mechanism: a loading platform and a working device; a slewing platform: a slewing main body, a slewing reducer and a slewing support; a slewing hydraulic system: a multi-way valve, a load-sensitive pump, a slewing buffer valve and a hydraulic motor. It can be seen that the slewing system includes not only mechanical structures but also hydraulic systems, and belongs to typical complex equipment. When constructing the digital twin platform of the slewing system, there are technical difficulties such as difficulty in low-delay real-time data return, difficulty in accurate characterization of hydraulic models, and time-varying inertia caused by load fluctuation and change of boom rotation angle.

[0033] As shown in Figure 1 The construction of the digital twin platform of the slewing system is carried out by using four systems, including a data system, a model system, an application system and an interaction system.

[0034] The data system mainly realizes real-time transmission and interaction of data. It realizes accurate collection, transmission and storage of data, and realizes accurate and real-time interaction with each system through a data interface, so as to assist the platform in real-time simulation calculation, state monitoring, performance evaluation and three-dimensional display. The process is as shown in Figure 2As shown, the field data is collected by a customized acquisition instrument and packaged and uploaded to the cloud server, and the data will be unpacked from the cloud to the database in the digital twin platform. This embodiment uses LabVIEW (Laboratory Virtual Instrument Engineering Workbench, a graphical programming language that uses icons instead of text lines to create applications, which can be used as a general-purpose program development environment / programming system) as a data transfer station, and realizes the addition, deletion, modification and query of data in the database through SQL statements. LabVIEW transmits data to the remaining three systems through the Http protocol for simulation calculation, state monitoring and performance evaluation, and three-dimensional display.

[0035] The model system mainly uses a universal simulation software to build high-fidelity models of various hydraulic elements and mechanical elements in the rotary system, such as multi-way valves, load-sensitive pumps, buffer valves, motors, speed reducers, rotational inertia, etc. The mechanical model of the equipment is developed twice to realize the reduction from three-dimensional to one-dimensional, improve the model simulation operation speed, combine the element models built into a system circuit and set parameters, and finally compare the simulation curves of the elements and the system with the experimental curves, and continuously correct the simulation model. The finally built simulation model of the complex equipment rotary system is as shown in Figure 3 .

[0036] The rotary inertia of the rotary system in this embodiment is complex and the calculation is complicated. The inertia operation in the model seriously affects the simulation operation speed of the digital twin. In order to meet the real-time requirements of the digital twin platform simulation, the rotary inertia of the upper car mechanism in the model needs to be simplified. The entire upper car mechanism is composed of an upper car platform and a working device, and according to the parallel axis theorem of rotational inertia, the rotational inertia of each part of the working device is superimposed on the rotary shaft. The total rotational inertia J z is fitted by three-dimensional software and data analysis software as a function of the boom rotation angle β: J z = -18576.83391 * β + 2.35517e+6.

[0037] The model system in the embodiment is built by using Amesim (Advanced Modeling Environment for performing Simulation of engineering systems), and a rotating inertia model is secondarily developed by using a Modelica editor to increase two input ports. One port synchronously modifies the size of the output rotating inertia according to the real-time swing arm rotation angle data. The other port calibrates the initial angle of the digital twin model according to the initial posture of the host.

[0038] Based on real-time interaction data and simulation calculation results, the application system jointly uses database big data analysis as a basis, uses nonlinear information processing technology, evaluates the equipment running state and system performance, and performs planned maintenance to avoid sudden failures. In specific implementation, a performance evaluation model is built by using Python (Python is a high-level scripting language combining interpretability, compilation, interactivity and object-orientedness), and based on the powerful interactive communication function of LabVIEW, field data characteristic values are extracted and real-time analysis is performed.

[0039] In the embodiment, the application system develops a performance evaluation model by using Python, uses CNN (convolutional neural network) to extract high-dimensional spatial features of sensors, reduces the feature dimension of data, realizes feature extraction of the rotating system data, and the feature data can accurately express the state and performance of the rotating system in the entire rotating process. Using feature data is conducive to simplifying the model and reducing the calculation amount of the model.

[0040] The interaction system provides corresponding function modules for the online visualization, state detection and performance evaluation of the digital twin platform, integrates various information systems such as data transmission and data analysis, and realizes the functions of rotating system running state monitoring, performance evaluation, real-time data information and three-dimensional posture visualization under the support of the model system and the application system, and helps to carry out reliability operation and maintenance services.

[0041] In the embodiment, the interface of the interaction system is as shown in Figures 4-8 , the home page interface of human-computer interaction is as shown in Figure 4 , the fault display interface is as shown in Figure 5 , the dial display interface is as shown in Figure 6 , the trend curve interface is as shown in Figure 7 , and the complex equipment posture display interface is as shown in Figure 8The monitoring parameters, performance parameters and attitude parameters of the complex equipment can be presented through a digital twin platform in a dashboard interface and a three-dimensional model. The three modules in the technical implementation process are designed and implemented in detail, which are: simulation model interaction, communication interface and data visualization; the simulation model interaction mainly realizes the calling of the simulation model in the model system; the communication interface realizes the data transmission between the data system, the model system, the application system and the interaction system; the data visualization includes the display of the state parameters in the running process of the slewing system and the dynamic demonstration of the three-dimensional model.

[0042] Specifically, the steps of the general construction method of the digital twin platform of the slewing system in the embodiment of the application include:

[0043] S1, real-time collection of main data such as physical prototype attitude data, hydraulic system parameters and controller internal parameters through high-performance sensors;

[0044] S2, real-time return of data to a cloud database through a 4G network, a data transmission link and a data automatic processing algorithm;

[0045] Among them, the data collection, transmission and communication rate is not less than 50Hz, the total delay is less than 6s, and the data local loop storage is 6 months.

[0046] S3, taking real-time field data as basic data, classifying and identifying the features of the basic data;

[0047] S4, simplifying the moment of inertia of the loading mechanism in the model, superimposing the moments of inertia of each part of the working device on the slewing shaft, and fitting the total moment of inertia J through three-dimensional software and data analysis software z and the function of the boom rotation angle β;

[0048] S5, secondary development of the moment of inertia model through a model editor, synchronous modification of the size of the output moment of inertia, and calibration of the initial angle of the digital twin model slewing;

[0049] S6, high-fidelity model building of each hydraulic element and mechanical element in the slewing system by using a universal simulation software, secondary development of the mechanical model of the equipment, realization of three-dimensional to one-dimensional reduction processing, improvement of the model simulation operation speed, combination of the element model built into a system circuit and parameter setting;

[0050] S7, development of a performance evaluation model through Python, and development of a fault diagnosis and prediction algorithm for critical components.

[0051] S8, simulation of the slewing system and various elements in the system based on the classified data and the identified features;

[0052] S9, based on real-time interaction data and simulation calculation results, combined with database big data analysis, using nonlinear information processing technology, evaluating the equipment running state and system performance, realizing the posture reproduction of the equipment, system parameter identification, simulation verification, running state monitoring and performance evaluation;

[0053] S10, establishing a data path between the simulation model, the instrument display interface and the three-dimensional visualization software part, so that the data in the digital twin model can be dynamically displayed on the basis of the three-dimensional model of the rotating system.

[0054] S11, based on real-time simulation results, real-time display of the equipment state.

[0055] Among them, S1-S3 are executed by the data system, S4-S6 are executed by the model system, S7-S9 are executed by the application system, and S10-S11 are executed by the interaction system.

[0056] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A general method for constructing a digital twin platform for complex equipment, characterized by: include: The data system uses high-performance sensors to collect real-time data on the physical prototype's posture, hydraulic system parameters, and controller internal parameters, and transmits the data back to the cloud database in real time. Use the real-time field data as the basic data of the data system, and perform data classification and feature recognition on the basic data; The model system uses universal simulation software to build high-fidelity models of various hydraulic and mechanical components in complex equipment, and conducts secondary development of the mechanical model of the equipment to achieve three-dimensional to one-dimensional order reduction. The built component models are combined into system loops and parameter settings are performed. Among them, the model system simplifies the moment of inertia of the vehicle loading mechanism in the three-dimensional model, and according to the parallel axis theorem of moment of inertia, the moment of inertia of each part of the working device is superimposed on the rotary axis, and the total moment of inertia is fitted through three-dimensional software and data analysis software. J z Angle with boom β The function is: J z =-18576.83391* β +2.35517e+6; The application system uses Python to develop a performance evaluation model and a key component fault diagnosis and prediction algorithm. Based on the data classification and feature recognition results obtained by the data system, the simulation results of the model system are used for performance evaluation calculations, thus achieving equipment posture reproduction, system parameter identification, simulation verification, operation status monitoring and performance evaluation. The interactive system establishes a data path between the simulation model, instrument display interface, and 3D visualization software, enabling data in the digital twin model to be dynamically displayed based on the complex 3D model of the equipment. Based on real-time simulation results, the equipment status is displayed and output in real time. In the data system, SQL statements are used to implement data storage and reading operations in the database, and the HTTP protocol is used to transmit the data to the application system for performance evaluation and analysis. At the same time, the corresponding data is transmitted to the model system and the interactive system for simulation calculation and animation display; the model system uses universal simulation software to build models of complex equipment, integrating the two major systems of mechanical and hydraulic.

2. A general method for constructing a digital twin platform for complex equipment according to claim 1, characterized in that: Transmit data back to the cloud database in real time, including: Data is transmitted back to the cloud database in real time via the 4G network and data transmission link.

3. The general method for constructing a digital twin platform for complex equipment according to claim 1, characterized in that: The application system uses the Http protocol to implement data interaction and transmits the data returned by the performance evaluation model to the interactive system.

4. The general method for constructing a digital twin platform for complex equipment according to claim 1, characterized in that: The interactive system is also used to realize status monitoring of various components of complex equipment and data information management under the drive of the data system and the support of the model system.

5. The general method for constructing a digital twin platform for complex equipment according to claim 4, characterized in that: The interactive system provides real-time monitoring and reliable operation and maintenance services.

Images