A digital twin system for multi-wire diamond wire saw cutting machining

Abstract

This invention discloses a digital twin system for multi-wire diamond wire saw cutting, comprising: a digital twin machine tool, a machine tool model built based on NX MCD software, including a worktable, two spindle rollers located below the worktable, diamond wire wound on the two spindle rollers, and guide wheels driving the spindle rollers to rotate; each moving part is equipped with an MCD signal; the diamond wire forms multiple wire saws between the two spindle rollers, and the wire saws have cutting function, wire bow visualization function, and motion visualization function; a data acquisition and transmission module, which acquires external data and transmits it to the digital twin machine tool and the MCD signals of the moving parts for mapping and association; and a data display interface, which displays the external data in text form. This invention establishes a mapping relationship between real machining process data and a virtual twin model, realizing the mapping of machining process information on the virtual twin model, which will be of great significance for understanding the multi-wire cutting process and optimizing the multi-wire cutting process technology.

Description

Technical Field

[0001] This invention relates to the field of machine tool processing, and more particularly to a digital twin system for multi-wire diamond wire saw cutting. Background Technology

[0002] Multi-wire cutting is a machining method used to cut hard and brittle materials, transforming a substrate material from a single piece into multiple thin sheets. In multi-wire cutting, process parameters and wire saw wear both affect the machining quality. To deeply study the cutting process, a comprehensive understanding and acquisition of the machine tool's real-time machining status is needed for better process control and regulation. However, in terms of machine tool machining data mapping, there is a lack of effective data transmission, processing, and visualization mapping relationships.

[0003] Digital twins, as a novel intelligent manufacturing technology, enable the integration of physical products with their digital twins, achieving full-process visualization of information and ensuring timely information and feedback. They are widely used in the field of intelligent manufacturing. Therefore, applying digital twin technology to multi-wire cutting, through data acquisition, transmission, processing, and visualization, establishes a mapping relationship between real processing data and a virtual twin model, realizing the mapping of processing information onto the virtual twin model. This is of great significance for understanding the multi-wire cutting process and optimizing its technology. Summary of the Invention

[0004] The purpose of this invention is to solve the problem of lack of machining data mapping and process visualization in the existing digital twin technology of cutting machine tools.

[0005] The technical solution adopted by this invention to solve its technical problem is: to provide a digital twin system for multi-wire diamond wire saw cutting, comprising:

[0006] A digital twin machine tool, wherein the digital twin machine tool is a machine tool model built based on NX MCD software, the moving parts of the machine tool include a worktable for fixing the workpiece to be cut, two spindle rollers located below the worktable, diamond wire wound on the two spindle rollers, and guide wheels that drive the spindle rollers to rotate, each moving part is equipped with an MCD signal; the diamond wire is wound multiple times on the two spindle rollers to form multiple wire saws between the two spindle rollers, the wire saws have cutting function, wire bow visualization function, and motion visualization function;

[0007] The data acquisition and transmission module is used to acquire external data, including motion data and status data of the physical machine tool; the motion data is transmitted to the digital twin machine tool and mapped and associated with the MCD signals of the moving parts, so that the digital twin machine tool can simulate the motion state of the physical machine tool.

[0008] The data display interface presents the motion and status data of the physical machine tool in text form.

[0009] Preferably, the data acquisition and transmission module includes a machine tool PLC, external sensors, an analog-to-Ethernet module, and KEPServerEX 6 gateway software;

[0010] The process by which the data acquisition and transmission module acquires and transmits motion data of the physical machine tool is as follows: the machine tool PLC acquires the data and converts it into a Modbus protocol signal, which is then sent to the KEPServerEX 6 gateway software; the KEPServerEX 6 gateway software then sends the signal to the digital twin machine tool.

[0011] The process by which the data acquisition and transmission module acquires and transmits the status data of the physical machine tool is as follows: external sensors obtain motion data of the physical machine tool, convert it into electrical signals, and send it to the analog-to-Ethernet module; the analog-to-Ethernet module converts the electrical signals transmitted from the external sensors into Modbus protocol signals and sends them to the KEPServerEX 6 gateway software; the KEPServerEX 6 gateway software sends the Modbus protocol signals to the digital twin machine tool.

[0012] Preferably, the communication between the KEPServerEX 6 gateway software and the digital twin machine tool is OPC communication, and the digital twin machine tool obtains motion data of the OPC UA protocol through the OPC URL link.

[0013] Preferably, the external data also includes relevant data for implementing the cutting function. After the relevant data is converted into a Modbus protocol signal, it is sent to the digital twin machine tool through the KEPServerEX 6 gateway software.

[0014] Preferably, the cutting function of the wire saw is implemented by the following steps:

[0015] Define the movement direction of the wire saw as the Y-axis, define the direction perpendicular to the wire mesh as the Z-axis, and define the direction that is perpendicular to both the Y-axis and the Z-axis as the X-axis; divide each wire saw into several micro-blocks along the Y-axis, and each micro-block into several micro-segments along the X-axis; the independent wire saw micro-segments after the division of a single wire saw are geometric cubes that are closely arranged in both the X-axis and Y-axis directions.

[0016] Using the dynamic material function of NX MCD software, the workpiece to be cut is defined as a dynamic material; using the dynamic material blade function of NX MCD software, each independent wire saw micro-segment is defined as an independent dynamic material blade; the dynamic material blade is set to move simultaneously along the X-axis, Y-axis and Z-axis; the dynamic material blade can be set to be active or inactive. When active, the dynamic material blade has a material removal function for the dynamic material, indicating that the wire saw has a cutting effect on the workpiece to be cut.

[0017] Based on the relevant data from external data used to achieve the cutting function, the system controls whether to activate the dynamic material cutter and the displacement and speed data of the dynamic material cutter. Specifically, the relevant data from external data includes a switch signal controlling whether the dynamic material cutter corresponding to each independent wire saw micro-segment is activated, as well as the speed and displacement data after activation. Activating the dynamic material cutter utilizes the sequence editor function of NX MCD, automatically activating the dynamic material cutter at each processing time step. After the dynamic material cutter is activated, the contact area between the dynamic material and the dynamic material cutter disappears, thus creating the effect of the workpiece being cut by the wire saw.

[0018] Preferably, the external data also includes relevant data for realizing pantograph visualization, specifically the pantograph height of the physical machine tool collected by external sensors.

[0019] Preferably, the wire saw's wire bow visualization function is implemented by the following steps:

[0020] A small square corresponding to each wire saw is established with the same height reference. Based on the relevant data used in the external data to realize the visualization of the wire bow, the wire bow height of each wire saw is determined. The wire bow height is set to the distance between the small square of the corresponding wire saw and the height reference, so as to realize the display of the wire saw and wire bow during the cutting process.

[0021] Preferably, the motion visualization function of the wire saw is implemented by including the following steps:

[0022] A single wire saw is divided into several wire saw micro-segments. Using the point-on-line sub-function of NX MCD software, the generated micro-segments are combined into a whole. Kinematic pairs are established and MCD signals are configured for it. The MCD signals are then mapped to the motion data of the wire saw, so that the several wire saw micro-segments divided from the single wire saw move on the same motion trajectory, realizing the visualization of the wire saw cutting motion.

[0023] Preferably, the status data includes standby status, machining status, fault alarm status, ambient temperature and humidity, cutting fluid flow rate, real-time power, real-time temperature of each spindle, tension, and bow height; the motion data includes diamond wire movement speed, table movement speed, table swing angle, movement speed of each spindle, movement speed and displacement of each guide wheel, and the guide wheel includes take-up wheel, pay-off wheel and side guide wheel.

[0024] Preferably, the digital twin machine tool further includes a three-color light, wherein the three colors of the light indicate that the machine tool is in standby mode, processing mode, and fault alarm mode, respectively.

[0025] The present invention has the following beneficial effects:

[0026] (1) Establish a digital twin system, and through data collection, transmission, processing and visualization, establish a mapping relationship between real processing data and virtual twin model, so as to realize the mapping of processing information on virtual twin model;

[0027] (2) Establish cutting function, wire bow visualization function and motion visualization function for the wire saw of the digital twin machine tool. While simulating the real cutting situation, visualization can help to better understand the multi-wire cutting process and optimize the multi-wire cutting process.

[0028] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments, but the present invention is not limited to the embodiments. Attached Figure Description

[0029] Figure 1 This is a system structure diagram of an embodiment of the present invention;

[0030] Figure 2 This is a schematic diagram of a digital twin machine tool according to an embodiment of the present invention;

[0031] Figure 3 This is a schematic diagram of the cutting function of an embodiment of the present invention, wherein (a) is a cutting schematic diagram and (b) is a wire saw dividing schematic diagram;

[0032] Figure 4 This is a schematic diagram of the motion visualization function according to an embodiment of the present invention;

[0033] Figure 5 This is a schematic diagram illustrating the visual function of the bow line in an embodiment of the present invention. Detailed Implementation

[0034] See Figure 1 The diagram shown is a system structure diagram of an embodiment of the present invention, including...

[0035] Digital twin machine tool 1, a machine tool model built based on NX MCD software, includes a worktable for fixing the workpiece to be cut, two spindle rollers located below the worktable, diamond wire wound on the two spindle rollers, and guide wheels that drive the spindle rollers to rotate. Each moving part is equipped with an MCD signal. The diamond wire is wound multiple times on the two spindle rollers to form multiple wire saws between the two spindle rollers. The wire saws have cutting function, wire bow visualization function, and motion visualization function.

[0036] Data acquisition and transmission module 2 acquires external data, including motion data and status data of the physical machine tool; the motion data is transmitted to the digital twin machine tool and mapped and associated with the MCD signals of the moving parts, so that the digital twin machine tool can simulate the motion state of the physical machine tool.

[0037] Data display interface 3 displays the motion and status data of the physical machine tool in text form.

[0038] Specifically, this embodiment uses NX MCD software version 2212, utilizing its electromechanical concept design module to establish a digital twin machine tool. The key to this establishment lies in the association between the physical machine tool and the digital twin machine tool. Specifically, this is achieved by: establishing corresponding kinematic pairs for the moving parts of the digital twin machine tool; then creating speed control or position control on these kinematic pairs; and finally, corresponding the newly created MCD signals with the speed control or position control; and finally, associating external data with the MCD signals to complete the association between the external signals and the MCD signals, thereby realizing the association between the physical machine tool and the digital twin machine tool.

[0039] For details, see Figure 2 The diagram shown is a schematic of a digital twin machine tool according to an embodiment of the present invention. It includes a worktable 21, a spindle roller 22, a diamond wire 23, and guide wheels. The guide wheels include side guide wheels 24, a take-up reel 25, and a pay-off reel 26. The digital twin machine tool also includes a tri-color light 27, which illuminates in three colors to indicate that the machine tool is in standby mode, processing mode, and fault alarm mode, respectively.

[0040] Specifically, the external data also includes relevant data used to implement the cutting function, including switch signals that control whether each individual wire saw micro-segment is activated, as well as speed data and displacement data after activation; after the relevant data is converted into Modbus protocol signals, it is sent to the digital twin machine tool through KEPServerEX 6 gateway software.

[0041] See Figure 3The diagram shows a cutting function of an embodiment of the present invention. (a) is a cutting diagram where a diamond wire is wound multiple times around the spindle roller 22 to form multiple wire saws 28. The workpiece 4 to be cut is fixed on the worktable 21, and the worktable 21 controls the workpiece 4 to approach the wire saws 28 for cutting. (b) is a wire saw division diagram. The cutting function of the wire saw includes the following steps:

[0042] Define the movement direction of the wire saw as the Y-axis, define the direction perpendicular to the wire mesh as the Z-axis, and define the direction that is perpendicular to both the Y-axis and the Z-axis as the X-axis; divide each wire saw into several micro-blocks along the Y-axis, and each micro-block into several micro-segments along the X-axis; the independent wire saw micro-segments after the division of a single wire saw are geometric cubes that are closely arranged in both the X-axis and Y-axis directions.

[0043] Using the dynamic material function of NX MCD software, the workpiece to be cut is defined as a dynamic material; using the dynamic material blade function of NX MCD software, each independent wire saw micro-segment is defined as an independent dynamic material blade; the dynamic material blade is set to move simultaneously along the X-axis, Y-axis and Z-axis; the dynamic material blade can be set to be active or inactive. When active, the dynamic material blade has a material removal function for the dynamic material, indicating that the wire saw has a cutting effect on the workpiece to be cut.

[0044] The external data used to implement the cutting function controls whether to activate the dynamic material cutter, as well as the displacement and speed data of the dynamic material cutter. Specifically, the external data includes switch signals controlling the activation of each individual wire saw micro-segment, and the activated speed and displacement data. Activation of the dynamic material cutter utilizes the sequence editor function of NX MCD, automatically activating the dynamic material cutter at each machining time step. After activation, the contact area between the dynamic material and the dynamic material cutter disappears, resulting in the effect of the workpiece being cut by the wire saw. The external data also includes externally calculated data related to the wire saw's cutting function, including switch signals controlling the activation of each individual wire saw micro-segment, and the activated speed and displacement data. This externally calculated data is converted into Modbus protocol signals and sent to the digital twin machine tool via the KEPServerEX 6 gateway software.

[0045] Specifically, the dynamic material blade is set to be invisible, so that when the cutting function is implemented, the digital twin machine tool displays the effect of a wire saw cutting the workpiece to be cut.

[0046] For details, see Figure 4 The diagram shown illustrates the motion visualization function of an embodiment of the present invention, which includes the following steps:

[0047] The single wire saw 28 is divided into several wire saw micro segments. Using the point-on-line sub-function of NX MCD software, the generated micro segments are combined into a whole, kinematic pairs are established and MCD signals are configured. The MCD signals are then mapped to the motion data of the wire saw, so that the several wire saw micro segments divided from the single wire saw 28 move on the same motion trajectory, thus realizing the visualization of the wire saw cutting motion.

[0048] For details, see Figure 5 The diagram shown illustrates the pantograph visualization function according to an embodiment of the present invention, which includes the following steps:

[0049] A small square corresponding to each wire saw is established using the same height reference. The bow height of each wire saw is determined by external data, and the bow height is set to the distance between the small square corresponding to that wire saw and the height reference, thus realizing the display of the wire saw bow during the cutting process. The external data specifically refers to the bow height of the physical machine tool collected by external sensors.

[0050] Specifically, the data acquisition and transmission module includes a machine tool PLC, external sensors, an analog-to-Ethernet module, and KEPServerEX 6 gateway software;

[0051] The process by which the data acquisition and transmission module acquires and transmits motion data of the physical machine tool is as follows: the machine tool PLC acquires the data and converts it into a Modbus protocol signal, which is then sent to the KEPServerEX 6 gateway software; the KEPServerEX 6 gateway software then sends the signal to the digital twin machine tool.

[0052] The process by which the data acquisition and transmission module acquires and transmits the status data of the physical machine tool is as follows: external sensors obtain motion data of the physical machine tool, convert it into electrical signals, and send it to the analog-to-Ethernet module; the analog-to-Ethernet module converts the electrical signals transmitted from the external sensors into Modbus protocol signals and sends them to the KEPServerEX 6 gateway software; the KEPServerEX 6 gateway software sends the Modbus protocol signals to the digital twin machine tool.

[0053] Specifically, the status data includes standby status, machining status, fault alarm status, ambient temperature and humidity, cutting fluid flow rate, real-time power, real-time temperature of each spindle, tension, and bow height; the motion data includes diamond wire movement speed, table movement speed, table oscillation angle, spindle movement speed, and guide wheel movement speed and displacement, wherein the guide wheels include take-up reels, pay-off reels, and side guide wheels. For guide wheel displacement and speed that the machine tool PLC cannot provide, external sensors are used to collect them.

[0054] When it is difficult to collect external data or there are other simulation needs, you can choose not to use the external data collected by the data acquisition and transmission module to associate with the MCD signal of the digital twin machine tool, but instead directly generate simulated data to associate with the MCD signal. In this case, the digital twin machine tool displays simulated processing conditions and does not correspond to the physical machine tool.

[0055] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A digital twin system for multi-wire diamond wire saw cutting, characterized in that, include: A digital twin machine tool, wherein the digital twin machine tool is a machine tool model built based on NX MCD software, the moving parts of the machine tool include a worktable for fixing the workpiece to be cut, two spindle rollers located below the worktable, diamond wire wound on the two spindle rollers, and guide wheels that drive the spindle rollers to rotate, each moving part is equipped with an MCD signal; the diamond wire is wound multiple times on the two spindle rollers to form multiple wire saws between the two spindle rollers, the wire saws have cutting function, wire bow visualization function, and motion visualization function; The data acquisition and transmission module is used to acquire external data, including motion data and status data of the physical machine tool; the motion data is transmitted to the digital twin machine tool and mapped and associated with the MCD signals of the moving parts, so that the digital twin machine tool can simulate the motion state of the physical machine tool. The data display interface shows the motion and status data of the physical machine tool in text form; The cutting function of the wire saw is implemented by the following steps: Define the movement direction of the wire saw as the Y-axis, define the direction perpendicular to the wire mesh as the Z-axis, and define the direction that is perpendicular to both the Y-axis and the Z-axis as the X-axis; divide each wire saw into several micro-blocks along the Y-axis, and each micro-block into several micro-segments along the X-axis; the independent wire saw micro-segments after the division of a single wire saw are geometric cubes that are closely arranged in both the X-axis and Y-axis directions. Using the dynamic material function of NX MCD software, the workpiece to be cut is defined as a dynamic material; using the dynamic material blade function of NX MCD software, each independent wire saw micro-segment is defined as an independent dynamic material blade; the dynamic material blade is set to move simultaneously along the X-axis, Y-axis and Z-axis; the dynamic material blade can be set to be active or inactive. When active, the dynamic material blade has a material removal function for the dynamic material, indicating that the wire saw has a cutting effect on the workpiece to be cut. Based on the relevant data from external data used to achieve the cutting function, the system controls whether to activate the dynamic material cutter and its displacement and speed data. Specifically, the relevant data includes a switch signal controlling the activation of the dynamic material cutter corresponding to each independent wire saw micro-segment, as well as the activated speed and displacement data. Activation of the dynamic material cutter utilizes the sequence editor function of NX MCD, automatically activating the dynamic material cutter at each processing time step. After activation, the contact area between the dynamic material and the dynamic material cutter disappears, resulting in the effect of the workpiece being cut by the wire saw. The wire saw's wire bow visualization function is implemented through the following steps: Establish small squares corresponding to each wire saw with the same height reference. Based on the relevant data in the external data used to realize the visualization of the wire bow, determine the wire bow height of each wire saw. Set the wire bow height to the distance between the small square of the corresponding wire saw and the height reference to realize the display of the wire saw and wire bow during the cutting process. The motion visualization function of the wire saw is implemented by the following steps: A single wire saw is divided into several wire saw micro segments. Using the point-on-line sub-function of NX MCD software, the generated micro segments are combined into a whole, a kinematic pair is established and the MCD signal is configured. The MCD signal is then mapped to the motion data of the wire saw, so that the several wire saw micro segments divided from the single wire saw move on the same motion trajectory, thus realizing the visualization of the wire saw cutting motion. The status data includes standby status, machining status, fault alarm status, ambient temperature and humidity, cutting fluid flow rate, real-time power, real-time temperature of each spindle, tension, and bow height; the motion data includes diamond wire movement speed, table movement speed, table swing angle, movement speed of each spindle, and movement speed and displacement of each guide wheel, wherein the guide wheels include take-up reel, pay-off reel, and side guide wheels.

2. The digital twin system for multi-wire diamond wire saw cutting according to claim 1, characterized in that, The data acquisition and transmission module includes a machine tool PLC, external sensors, an analog-to-Ethernet module, and KEPServerEX 6 gateway software; The process by which the data acquisition and transmission module acquires and transmits motion data of the physical machine tool is as follows: the machine tool PLC acquires the data and converts it into a Modbus protocol signal, which is then sent to the KEPServerEX 6 gateway software; the KEPServerEX 6 gateway software then sends the signal to the digital twin machine tool. The process by which the data acquisition and transmission module acquires and transmits the status data of the physical machine tool is as follows: external sensors obtain the status data of the physical machine tool, convert it into an electrical signal, and send it to the analog-to-Ethernet module; the analog-to-Ethernet module converts the electrical signal transmitted from the external sensor into a Modbus protocol signal and sends it to the KEPServerEX 6 gateway software; the KEPServerEX 6 gateway software sends the Modbus protocol signal to the digital twin machine tool.

3. The digital twin system for multi-wire diamond wire saw cutting according to claim 2, characterized in that, The communication between the KEPServerEX 6 gateway software and the digital twin machine tool is OPC communication. The digital twin machine tool obtains motion data of the OPC UA protocol through the OPC URL link.

4. The digital twin system for multi-wire diamond wire saw cutting according to claim 2, characterized in that, The relevant data used to implement the cutting function in the external data is converted into Modbus protocol signals and then sent to the digital twin machine tool through the KEPServerEX 6 gateway software.

5. The digital twin system for multi-wire diamond wire saw cutting according to claim 2, characterized in that, The external data used to visualize the pantograph specifically refers to the pantograph height of the physical machine tool collected by external sensors.

6. The digital twin system for multi-wire diamond wire saw cutting according to claim 1, characterized in that, The digital twin machine tool also includes a three-color light, which illuminates in three different colors to indicate that the machine tool is in standby mode, processing mode, and fault alarm mode, respectively.

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