A virtual commissioning method for an ultrasonic seam welder

Abstract

The present application belongs to the technical field of software debugging, and relates to a virtual debugging method for an ultrasonic roll welding machine, which comprises the following steps: three-dimensional model establishment, digital twin construction, virtual control design, glass conveying simulation, alignment state simulation, down-pressing test and roll welding process test. The virtual debugging method can take into account the various parameters involved in glass conveying, glass alignment, roll welding wheel down-pressing and roll welding process, and realizes virtual debugging of the ultrasonic roll welding machine in the form of joint simulation. Through the establishment of digital twins, true simulation is carried out, and theoretical analysis and finite element method analysis are carried out, which not only ensures real-time performance but also achieves high accuracy.

Description

Technical Field

[0001] This invention relates to the field of software debugging technology, and in particular to a virtual debugging method for ultrasonic roll welding machines. Background Technology

[0002] The installation of busbars for thin-film solar panels requires ultrasonic roll welding to attach the busbars to the photovoltaic panels. The production method involves horizontally conveying the photovoltaic panels using a conveyor, and then using welding rollers to roll and press the busbars onto the surface of the photovoltaic panels, thus ultrasonically welding the busbars to the panels.

[0003] After using automated equipment, adjustments need to be made for different products, which will bring some new problems:

[0004] 1) There is no theoretical basis for controlling the pressure range of the welding head during the welding process. If the pressure is too high, the film layer may be welded through or the glass may be crushed. If the pressure is too low, the weld may not be able to be made.

[0005] 2) Ultrasonic metal roll forming welding is completed under instantaneous pressure and high-frequency ultrasonic excitation. The welding process is characterized by its speed, complexity, variability, and influence by multiple parameters. During and after welding, the equipment generates stress and deformation to a certain extent, such as residual welding deformation, welding shrinkage, and welding warping. These factors subsequently affect workpiece deformation, welding defects, the weldability of the workpiece structure, and the brittle fracture strength, fatigue strength, yield strength, and vibration characteristics of the component, ultimately impacting the machining accuracy and dimensional stability of the welded workpiece. Therefore, predicting welding thermal stress and deformation is very difficult and lacks foresight. Only by comprehensively predicting and analyzing the impact of welding on the mechanical properties of the entire welded workpiece can the welding quality be objectively evaluated.

[0006] 3) Due to the variety of physical properties of the upper and lower welding surfaces, and the openness of the welding environment, it is difficult to isolate and study a particular parameter without special experimental methods and equipment.

[0007] 4) The welding process requires high flatness of the glass support surface, but the flatness of the equipment is difficult to characterize in real time during dynamic testing. In fact, in the mass production process, it is difficult to obtain the material selection and thickness requirements of my support plate through experimental analysis.

[0008] 5) Obtaining stable equipment parameters through debugging requires significant man-hours and material consumption. Furthermore, addressing potential thermal stress on the welding surface may necessitate the fabrication of additional stress-relieving equipment (such as a welding strip preheating device). The process parameters and power output of these devices require repeated testing on the equipment in traditional processes, incurring both high costs and time, while also posing a risk of equipment damage and resulting in substantial resource waste.

[0009] Chinese patent CN113801666A discloses a virtual-real combined large coke oven mechanical equipment debugging system, which comprises: a PLC module responsible for running the coal loading car program, a PLC module responsible for running the coke pushing machine program, a PLC module responsible for running the coke blocking machine program, a PLC module responsible for running the electric locomotive program, a PLC module responsible for running the ground coordination program, an OPC module for installing compatible main controller hardware device interface system, a computer for process virtual debugging platform, an Ethernet switch module for communication, PLC and virtual debugging system access to the same switch LAN, AC220V / DC24V power conversion module for PLC module power supply. The scheme is mainly aimed at the action flow debugging of the equipment, and does not involve the multi-physical field simulation analysis of the equipment.

[0010] Chinese patent CN116029172 A discloses a method for solving maximum stress of mechanical arm real-time motion based on digital twinning, which can analyze equivalent stress of any posture of the mechanical arm and solve the maximum stress under the current state. However, the real-time motion of the mechanical arm here does not consider the influence of any physical field.

[0011] Therefore, it is necessary to design a virtual debugging method for the ultrasonic roll welding machine to solve the above problems. SUMMARY

[0012] The main purpose of the present application is to provide a virtual debugging method for the ultrasonic roll welding machine, which can avoid the damage of the vulnerable parts on the real equipment during the reciprocating test and calibration, save the scrap cost, shorten the debugging period, and save the time cost and labor cost.

[0013] The present application achieves the above-mentioned purpose through the following technical scheme: a virtual debugging method for the ultrasonic roll welding machine, the debugging system adopted comprises a 3D virtual engine software, an ansys software and a PLC, and the virtual debugging steps comprise:

[0014] S1, three-dimensional model establishment: digitize modeling of equipment, glass and solder strip, then import the digitized model into 3D virtual engine software to obtain a map model, the map model distinguishes virtual equipment, glass and solder strip by code, the virtual equipment includes a plurality of virtual actuators and virtual sensors, the virtual equipment includes a support platform, a conveying line passing through the support platform, a straightening mechanism located around the air floating platform, a linear module located at the side of the air floating platform, a roller welding mechanism driven by the linear module, the support platform is provided with a suction pipe and a blowing pipe, the straightening mechanism includes a plurality of straightening air cylinders, the roller welding mechanism includes a roller welding wheel; the virtual actuators include a suction electromagnetic valve and a vacuum generator on the suction pipe, a blowing electromagnetic valve located on the blowing pipe, a straightening electromagnetic valve for controlling the charging and discharging of the straightening air cylinder, a servo motor in the linear module, a rotating motor for driving the rotation of the roller welding wheel, an ultrasonic assembly and a cooling assembly located on the roller welding wheel, and a down pressure air cylinder for driving the down pressure of the roller welding wheel; the virtual sensors include a travel switch for detecting the arrival of the glass on the air floating platform and a pressure sensor for detecting the down pressure of the down pressure air cylinder;

[0015] S2, digital twin construction: programming in the 3D virtual engine software using C# language, defining the properties of glass, solder strip and physical field by code, the working mode of all virtual actuators and virtual sensors and the cooperation mode between the virtual equipment and the structure, forming a virtual digital twin, the properties of the glass include glass size, glass quality, friction coefficient and material strength, the properties of the solder strip include solder strip size, solder strip stiffness and solder strip thermal deformation ability, the physical field includes gravity field, stress field, airflow field and liquid flow field;

[0016] S3, virtual control design: define the interactive control software as a virtual debugging interface to realize the event input of PLC, the action execution of virtual actuators and the condition feedback of virtual sensors, and define the input interface to realize the information interaction between 3D virtual engine software and ansys software, send the relative position relationship and interaction force in the map model to ansys software in real time through the built-in code of 3D virtual engine software, the PLC sends control instructions to drive each virtual actuator to work, and then each virtual sensor feeds back detection information to the PLC, the finite element analysis of ansys is realized by code, the finite element analysis result data is called by the 3D virtual engine software in the form of dat file, and the 3D virtual engine software outputs the debugging state;

[0017] S4, glass conveying simulation: define the contact surface between the conveying belt and the glass, the conveying line moves the glass to the support platform, and the arrival position of the glass is sensed by the travel switch, so as to determine the relative position of the glass and the support platform;

[0018] S5, the state simulation: using the Fluent module in Ansys Workbench to analyze the air floating support process, opening the blowing electromagnetic valve, simulating the air flow of different gas flow to the glass support state, opening the correction electromagnetic valve, the finite element analysis will divide the glass into m x n finite element grids, and form the characteristic parameter matrix of m x n elements according to the stress of each finite element grid, according to the size of the support platform, the size of the glass and the position of the travel switch, the position of the finite element grid corresponding to the outlet of the blowing pipe can be confirmed, the gas flow in the blowing pipe corresponds to the force of the air flow field of the blowing pipe, when the force of the air flow field and the resultant force of the gravity and the internal stress of the finite element grid in the stress field are balanced, the optimal gas flow is obtained;

[0019] S6, the test of pressing down: using the static analyse module and Pre-stress modal module in Ansys to analyze, dividing the welding strip into M x 1 finite element grids, determining the relative position of the glass and the support platform after correction according to the size of the support platform, the size of the glass and the position of the correction mechanism, determining the finite element grid position corresponding to the suction pipe, and at the same time, according to the initial position of the linear module and the roll welding mechanism, the size of the glass and the size of the welding strip, the finite element grid on the glass and the welding strip corresponding to the roll welding wheel pressing down is determined, opening the suction electromagnetic valve and the vacuum generator, combining the suction pressure of the suction pipe, the pressure displayed by the pressure sensor, the stress of the glass and the welding strip in the gravity field and the stress field to obtain the characteristic parameter matrix of the glass and the welding strip, and according to the material strength of the glass and the stiffness of the welding strip, the pressure interval of the pressing down cylinder is obtained;

[0020] S7, the test of roll welding process: using the couple field transient module to analyze the stress of the welding strip and the welding condition under the condition of ultrasonic excitation and heat source coupling, according to the relative position of the equipment, the glass and the welding strip during correction, the rotating speed of the servo motor, the rotating speed of the rotating motor and the running time, the finite element grid position of the roll welding wheel acting on the glass and the welding strip is determined, the instantaneous pressure is determined according to the frequency of the electric signal of the ultrasonic assembly and the pressing down force of the pressing down cylinder, the instantaneous temperature of the roll welding wheel is determined according to the power of the ultrasonic assembly, the liquid flow field and the temperature in the cooling assembly, whether the welding rod starts to deform is confirmed, and whether the friction between the glass and the welding strip exceeds the static friction is calculated, and the optimal pressure value is obtained.

[0021] Specifically, the 3D virtual engine software is Unity, Unreal, QGS or Three.JS.

[0022] Further, the digital modeling is completed by using Solidworks software, and the fbx file is made by 3dMax and then imported into the 3D virtual engine software.

[0023] Specifically, the shader module is used for coloring processing of the three-dimensional model, the ansys finite element analysis result is called by the Unity software in the form of a dat file, and the obtained data is rendered by using the shader module to realize real-time display of the finite element of the device.

[0024] Specifically, when the PLC is a real PLC, the socket module in the Unity software is used to communicate with the functional device through TCP / IP protocol, the interactive control software is taken as a server and the virtual device is taken as a client, the connection between the server and the client is established, and the data information is interacted.

[0025] Specifically, when the PLC is a virtual PLC, the virtual PLC is given an IP address, so that the Unity software obtains and sends data from the IP address to each functional device.

[0026] Specifically, the debugging content includes at least one of frequency response analysis, dynamic analysis, ultrasonic impact analysis and thermal temperature field analysis.

[0027] The beneficial effects of the technical scheme of the present application are:

[0028] 1. The virtual debugging method avoids damage to the vulnerable parts on the real device during reciprocating test and calibration, saves the scrap cost, shortens the debugging period, and saves the time cost and labor cost;

[0029] 2. Each parameter involved in glass conveying, glass correction, wheel pressing and rolling welding process can be considered, the virtual debugging of the ultrasonic rolling welding machine is realized in the form of joint simulation, simulation is carried out by establishing a digital twin, and theoretical analysis and finite element method analysis are carried out, which ensures real-time performance and high accuracy. BRIEF DESCRIPTION OF DRAWINGS

[0030] Fig. 1 It is a framework diagram of the virtual debugging system;

[0031] Fig. 2 It is a control flow chart of the virtual debugging method;

[0032] Fig. 3 It is a detailed flow chart of the simulation work of the ultrasonic rolling welding machine. DETAILED DESCRIPTION

[0033] The present application will be further described in detail below in combination with specific embodiments.

[0034] Embodiment:

[0035] As Figs. 1 to 3 shown, a virtual debugging method for an ultrasonic seam welder, the debugging system includes Unity software (a game engine used as a virtual debugging engine in virtual debugging software), ansys software (a finite element analysis software) and PLC (programmable logic controller), the virtual debugging steps include:

[0036] S1, three-dimensional model establishment: using Solidworks software to digitally model the equipment, glass and solder strip, making a three-dimensional model through 3dMax, then converting the format to a map model of fbx file and importing it into Unity software to get a map model, the map model distinguishes virtual equipment, glass and solder strip by code, the virtual equipment includes a plurality of virtual actuators and virtual sensors, the virtual equipment includes a support platform, a conveying line passing through the support platform, a straightening mechanism located around the air floating platform, a linear module located at the side of the air floating platform, a seam welding mechanism driven by the linear module, the support platform is provided with a suction pipe and a blowing pipe, the straightening mechanism includes a plurality of straightening air cylinders, the seam welding mechanism includes a seam welding wheel; the virtual actuators include a suction electromagnetic valve and a vacuum generator on the suction pipe, a blowing electromagnetic valve located on the blowing pipe, a straightening electromagnetic valve for controlling the charging and discharging of the straightening air cylinder, a servo motor in the linear module, a rotating motor for driving the seam welding wheel to rotate, an ultrasonic assembly and a cooling assembly located on the seam welding wheel, and a down pressure air cylinder for driving the seam welding wheel to press down; the virtual sensors include a travel switch located on the blowing pipe to detect the arrival of the glass on the air floating platform, and a pressure sensor for detecting the pressure of the down pressure air cylinder. The map model is colored by using shader module (a surface processing plug-in built in Unity) to show the realistic appearance of the equipment and products, so as to facilitate the debugging personnel to distinguish the equipment and products and the various functional devices in the equipment.

[0037] Unity software is a 3D virtual engine software used to establish a model. In actual application, Unreal, QGS or Three.JS software can be used instead.

[0038] S2, digital twin construction: using C# language programming in Unity software, adopting code to define the properties of glass, solder strip and physical field, the working mode of all virtual actuators and virtual sensors and the cooperation mode between the virtual equipment and the internal structure, forming a virtual digital twin, the properties of glass include glass size, glass quality, friction coefficient and material strength, the properties of solder strip include solder strip size, solder strip stiffness and solder strip thermal deformation ability, the physical field includes gravity field, stress field, air flow field and liquid flow field.

[0039] The digital twin of the device in general virtual commissioning mainly includes the content, functional performance and event response of the device. This means that the digital twin of the device not only contains the basic data such as size and mass of the device, but also contains the mechanism of multi-dimensional, full-factor interconnection and real-time dynamic feedback interaction between the device in the virtual scene and the physical space production, manufacturing and operation information, so that the model has the characteristics of virtual-real fusion. For the geometry and structural mechanics performance of the device, its digital twin is established, and its essence is to use the scientific means of calculation and measurement to make the morphology and performance of the digital three-dimensional model infinitely approach the real physical equipment by adjusting the feasible parameters. For complex major equipment, this approach can be expressed as follows:

[0040] P eq ={P pf +P ch +P pa +P ca}

[0041] Wherein:

[0042]

[0043] In the formula, P eq represents the characteristic parameter matrix of the device, P pf represents the physical field matrix of the device, P ch represents the device characteristic matrix, P pa represents the basic physical parameter matrix of the device, and P ca represents the device calculation result matrix.

[0044] P eq is a state representing the simulation process of the device, which is a state matrix composed of P pf , P ch , P pa and P ca . The sufficient consideration of these characteristics enables the virtual model to dynamically, real-time, realistically and uniquely represent the corresponding virtual device. The reason why theoretical analysis results and finite element analysis results are used together to represent the device calculation results is that the mathematical principle of finite element is based on the differential deformation theory, which can be described by Taylor expansion. Its calculation method is to divide a complex structure into many tetrahedron or hexahedron structures. Although this calculation method is more accurate, it occupies a lot of resources. In the case of considering many factors, the operation period of finite element is often several times that of theoretical calculation. When doing device virtual commissioning, the working state of the device is dynamic, and theoretical analysis can be quickly analyzed and completed, but the finite element analysis result is inevitably lagging behind the theoretical calculation analysis result, so the method of combining theoretical calculation and finite element correction is adopted. The finite element analysis result matrix P有限元 The device calculates a result matrix P ca The theoretical analysis result and the finite element analysis result are included, and the finite element analysis result can correct the theoretical analysis result. For example, a device completes an action for 100 frames, the finite element analysis period is 10 frames, so only the finite element analysis is performed at the 10th, 20th, 30th, …, 100th frame, and the theoretical calculation of the device is performed by using a general calculation method of theoretical mechanics (directly realized by using a C# language) to obtain a theoretical value a of deformation; meanwhile, the correction value Δa of deformation is obtained from the finite element analysis result of the 10th, 20th, 30th, …, 100th frame, and the theoretical calculation value is corrected. In this way, the real-time performance of the analysis is ensured, and the accuracy of the analysis is improved.

[0045] S3, virtual control design: define the interactive control software as a virtual debugging interface, realize the event input of the PLC, the action execution of the virtual actuator, and the condition feedback of the virtual sensor, and define the input interface to realize the information interaction between the Unity software and the ansys software, send the relative position relationship and the interaction force in the map model to the ansys software in real time through the built-in code of the Unity software, the PLC sends a control instruction to drive each virtual actuator to work, and then each virtual sensor feeds back detection information to the PLC, the finite element analysis of the ansys is realized by using the code, the finite element analysis result data is called by the Unity software in the form of a dat file, and the Unity software outputs the debugging state.

[0046] The Socket class in the System.Net.Sockets namespace of the C# language is used to receive and send data, complete the communication between the interactive control software and the functional device, the interactive control software is used as a server, first creates a communication interface responsible for listening, and binds the IP address and the port number through the Bind function, then starts listening through the Listen function, and waits for the connection request of the client; the client creates a communication interface responsible for communication, the IP address and the port number are consistent with the server, sends a connection request to the server through the Connect function, at this time the server responds to the communication interface request of the client, establishes a connection with the client through the Accept function, and is used for transmitting data information.

[0047] The PLC can be real or virtual. When the PLC is real, the PLC communicates with the functional devices through a TCP / IP protocol using a socket module (communication interface) in the Unity software, with the interactive control software as a server and the virtual device as a client, to establish a connection between the server and the client for data information interaction. The PLC communicates with each functional device through a TCP / IP protocol. If the PLC is virtual, the virtual PLC is assigned an IP address, so that the Unity software obtains and sends data from the IP address to each functional device.

[0048] S4, glass conveying simulation: define the contact surface of the conveying belt and the glass, the conveying line moves the glass to the support platform, and the arrival position of the glass is sensed by using a travel switch, so as to determine the relative position of the glass and the support platform.

[0049] This process can confirm the position of the glass when it is in place.

[0050] S5, alignment state simulation: analyze the air floating support process by using the Fluent module in Ansys Workbench, open the air blowing electromagnetic valve, simulate the air flow of different gas flow to the glass support state, open the alignment electromagnetic valve, the finite element analysis will divide the glass into m x n finite element lattices, and form a characteristic parameter matrix of m x n elements according to the stress of each finite element lattice, according to the size of the support platform, the size of the glass and the position of the travel switch, the position of the finite element lattice corresponding to the outlet of the air blowing pipe can be confirmed, the gas flow in the air blowing pipe corresponds to the force of the air flow field of the air blowing pipe, when the force of the air flow field and the resultant force of the gravity and the internal stress of the finite element lattice in the stress field are balanced, the optimal gas flow is obtained.

[0051] This step can confirm the gas flow required for air floating.

[0052] S6, down pressure test: analyze by using the static analyse module and the Pre-stress modal module in Ansys, divide the solder strip into M x 1 finite element lattices, determine the relative position of the glass and the support platform after alignment according to the size of the support platform, the size of the glass and the position of the alignment mechanism, determine the finite element lattice position corresponding to the air suction pipe, and at the same time, according to the initial position of the linear module and the seam welding mechanism, the size of the glass and the size of the solder strip, determine the finite element lattice on the glass and the solder strip corresponding to the down pressure of the seam welding wheel, open the air suction electromagnetic valve and the vacuum generator, combine the air suction pressure of the air suction pipe, the pressure displayed by the pressure sensor, the stress of the glass and the solder strip in the gravity field and the stress field to obtain the characteristic parameter matrix of the glass and the solder strip, and according to the material strength of the glass and the stiffness of the solder strip, obtain the pressure interval of the down pressure cylinder.

[0053] In static pressure, first to ensure that the glass is not broken, so the step needs to be confirmed in advance down the approximate range of pressure.

[0054] S7, the roller welding process test: using couple field transient module analysis ultrasonic excitation and heat source coupling conditions of the welding strip stress and welding situation, according to the relative position of the equipment, glass and welding strip, the speed of the servo motor, the speed of the rotating motor and the running time to determine the finite element lattice position of the roller wheel acting on the glass and the welding strip, according to the frequency of the ultrasonic assembly and the down pressure of the down cylinder to determine the transient pressure, according to the power of the ultrasonic assembly, the liquid flow field and temperature in the cooling assembly to determine the transient temperature of the roller wheel, and confirm whether the welding rod starts to heat deformation, and calculate whether the friction between the glass and the welding strip exceeds the static friction, get the optimal pressure value.

[0055] The problems need attention in the process of roller welding come from two aspects, one is in the state of ultrasonic excitation, the down pressure is variable, so it is necessary to ensure that no matter where the roller wheel runs, the glass cannot be broken, so there is a requirement for the maximum value of the down pressure; Another is that the welding strip will soften and deform when heated, and the welding strip must be able to be welded to the glass under sufficient pressure, so there is also a requirement for the minimum value of the down pressure. The two aspects have many related elements, and the optimal value of the down pressure needs to be defined in advance to simulate.

[0056] From the economic benefits, the core of the ultrasonic roller welding machine is the ultrasonic roller welding mechanism and its accessories, among which the cost of the ultrasonic roller welding mechanism is about 100,000 yuan, and the cost of the accessories is about 30,000 yuan. The above two types of equipment are consumables, that is, during the equipment debugging process, due to improper control of the down pressure and the heating device, it is easy to cause damage to the equipment, and once damaged, it will cause a lot of scrap cost. Through virtual debugging, the above equipment can be avoided from being damaged due to reciprocating test, so the investment is saved.

[0057] From the R&D cycle, the debugging cycle of single machine equipment in domestic photovoltaic industry is generally 2 weeks to 1 month (floating up and down according to the complexity of the equipment). The development process of the equipment is generally as follows: two-dimensional layout (scheme design) → three-dimensional drawing (engineering design stage) → two-dimensional drawing (drawing stage) → machining → mechanical assembly (including rework) → electrical assembly → electrical debugging → packaging and shipping. Among them, after completing the three-dimensional drawing design, the electrical engineer can design the circuit diagram and control program according to the three-dimensional model and equipment list. The completion time of this process is generally the same as the time of two-dimensional mechanical drawing. And the debugging of the control program can only start after the electrical assembly is completed. Through the layout of this project, the debugging time of the equipment after assembly can be allocated to the virtual end in the early stage, and the control logic and the rationality of the equipment design are verified by using digital twin. Through this method, for a 3-month R&D project, the debugging cycle can be reduced by about 2 weeks, which obviously saves the time cost.

[0058] Taking the unit as an example, according to the current order quantity, it is assumed that 800 new equipment need to be debugged every year, which requires 800 person-time of debugging time. Assuming that the debugging cycle of each equipment in the factory and on the customer's site is 2 months, as long as the time is shortened by 2 weeks, according to the debugging cost of 5,000 yuan per person-time, 4 million yuan of human cost can be saved.

[0059] The above only describes some embodiments of the present application. For ordinary skilled persons in the art, without departing from the concept of the present application, several modifications and improvements can be made, which are all within the protection scope of the present application.

Claims

1. A virtual debugging method for an ultrasonic roll welding machine, the debugging system comprising 3D virtual engine software, ANSYS software, and PLC, characterized in that: The virtual debugging steps include: S1. 3D Model Establishment: Digital models of the equipment, glass, and welding strip are created and then imported into a 3D virtual engine software to obtain texture models. These texture models use code to distinguish virtual equipment, glass, and welding strips. Each virtual device includes several virtual actuators and virtual sensors. The virtual device includes a support platform, a conveyor line passing through the support platform, a alignment mechanism located around the air-float platform, a linear module located on the side of the air-float platform, and a roll welding mechanism driven by the linear module. The support platform contains an air intake pipe and an air blowing pipe. The alignment mechanism includes several... The dry alignment cylinder includes a welding mechanism comprising a welding wheel; the virtual actuator includes an intake solenoid valve and a vacuum generator on the intake pipe, a blowing solenoid valve on the blowing pipe, a alignment solenoid valve for controlling the inflation and deflation of the alignment cylinder, a servo motor in the linear module, a rotary motor for driving the welding wheel to rotate, an ultrasonic component and a cooling component on the welding wheel, and a pressing cylinder for driving the welding wheel to press down; the virtual sensor includes a limit switch located on the blowing pipe to detect when the glass reaches the air-float platform and a pressure sensor for detecting the downward pressure of the pressing cylinder. S2. Digital Twin Construction: In the 3D virtual engine software, C# language is used for programming. The properties of glass, welding strip, and physical field are defined by code. The working mode of all virtual actuators and virtual sensors and the coordination mode between the internal structure of the virtual device are formed to create a virtual digital twin. The properties of the glass include glass size, glass mass, coefficient of friction, and material strength. The properties of the welding strip include welding strip size, welding strip stiffness, and welding strip thermal deformation capability. The physical field includes gravity field, stress field, airflow field, and liquid flow field. S3. Virtual Control Design: Define interactive control software as a virtual debugging interface to realize PLC event input, virtual actuator action execution, and virtual sensor status feedback. Define input interface to realize information interaction between 3D virtual engine software and ANSYS software. The 3D virtual engine software sends the relative positional relationships and interaction forces in the texture model to ANSYS software in real time through built-in code. The PLC sends control commands to drive each virtual actuator to work. Then, each virtual sensor feeds back detection information to the PLC. The finite element analysis of ANSYS is implemented using code. The finite element analysis results are called by the 3D virtual engine software in the form of a .dat file. The 3D virtual engine software outputs the debugging status. S4. Glass conveying simulation: Define the contact surface between the conveyor belt and the glass. The conveyor line moves the glass to the support platform. The limit switch senses the arrival position of the glass to determine the relative position of the glass and the support platform. S5. Correction State Simulation: The Fluent module in Ansys Workbench is used to analyze the air-bearing support process. The blowing solenoid valve is opened to simulate the airflow support state of the glass under different gas flow rates. The correction solenoid valve is opened, and the finite element analysis divides the glass into m×n finite element lattices. Based on the force of each finite element lattice, a characteristic parameter matrix of m×n elements is formed. Based on the size of the support platform, the size of the glass, and the position of the limit switch, the finite element lattice position corresponding to the outlet of the blowing pipe can be determined. The gas flow rate in the blowing pipe corresponds to the force of the airflow field in the blowing pipe. When the force of the airflow field is balanced with the resultant force of the gravity on the finite element lattice in the gravitational field and the internal stress on the stress field, the optimal gas flow rate is obtained. S6. Downward Pressure Test: The static analyze module and pre-stress modal module in ANSYS are used for analysis. The weld strip is divided into M×1 finite element lattices. The relative position of the glass and the support platform after correction is determined according to the size of the support platform, the size of the glass, and the position of the correction mechanism. The finite element lattice position corresponding to the suction pipe is determined. At the same time, the finite element lattices on the glass and weld strip corresponding to the downward pressure of the welding wheel are determined according to the initial position of the linear module and the roller welding mechanism, the size of the glass, and the size of the weld strip. The suction solenoid valve and the vacuum generator are opened. The characteristic parameter matrix of the glass and weld strip is obtained by combining the suction pressure of the suction pipe, the pressure displayed by the pressure sensor, and the forces on the glass and weld strip in the gravitational field and stress field. The pressure range of the downward pressure cylinder is obtained according to the material strength of the glass and the stiffness of the weld strip. S7. Roll Welding Process Test: The coupled field transient module is used to analyze the stress and welding conditions of the welding strip under ultrasonic excitation and heat source coupling conditions. Based on the relative positions of the equipment, glass and welding strip during correction, the rotation speed of the servo motor, the rotation speed of the rotary motor and the running time, the finite element lattice position of the welding roller acting on the glass and welding strip is determined. The instantaneous pressure is determined based on the electrical signal frequency of the ultrasonic component and the downward pressure of the downward pressure cylinder. The instantaneous temperature of the welding roller is determined based on the power of the ultrasonic component, the liquid flow field and temperature in the cooling component, and it is confirmed whether the welding rod has started to deform thermally. It is also calculated whether the friction between the glass and the welding strip exceeds the static friction to obtain the optimal pressure value.

2. The virtual debugging method for an ultrasonic roll welding machine according to claim 1, characterized in that: The 3D virtual engine software is Unity, Unreal, QGS, or Three.JS.

3. The virtual debugging method for an ultrasonic roll welding machine according to claim 2, characterized in that: The digital modeling was completed using Solidworks software. The model was created using 3ds Max, then converted to an FBX file and imported into the 3D virtual engine software.

4. The virtual debugging method for an ultrasonic roll welding machine according to claim 1, characterized in that: The 3D model is colored using the shader module, and the finite element analysis results are reflected in the current state of the texture model. The finite element analysis of the device is then rendered using the shader module.

5. The virtual debugging method for an ultrasonic roll welding machine according to claim 1, characterized in that: When the PLC is a real PLC, the socket module in the 3D virtual engine software is used to communicate with the functional devices via the TCP / IP protocol. The interactive control software acts as the server and the virtual device acts as the client, establishing a connection between the server and the client to exchange data information.

6. The virtual debugging method for an ultrasonic roll welding machine according to claim 1, characterized in that: When the PLC is a virtual PLC, the 3D virtual engine software assigns an IP address to the virtual PLC, enabling the 3D virtual engine software to obtain and send data to various functional devices from that IP address.

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