Bullet train bogie replacement equipment interaction control system and method based on digital twinning

Abstract

The invention discloses an interactive control system and method for bullet train bogie replacement equipment based on digital twinning. The interactive control system comprises a pairing module, a synchronization module and a simulation module. The interaction control method comprises the following steps: determining a bullet train bogie replacement equipment physical entity and a corresponding bullet train bogie replacement equipment virtual entity, and determining a conversion relation based on the bullet train bogie replacement equipment physical entity and the virtual entity; according to the virtual entity motion data, the motion posture of the bullet train bogie replacement equipment physical entity is mapped to the bullet train bogie replacement equipment virtual entity, and the poses of the bullet train bogie replacement equipment physical entity and the bullet train bogie replacement equipment virtual entity are synchronized; and simulating a mechanism moving track according to the virtual moving posture of the equipment. Matching of the front portion and the rear portion in the operation process of the bogie replacement equipment is optimized, and the operation efficiency is improved; dangerous operation in equipment replacement operation of the bullet train bogie is subjected to virtual simulation before operation, and the safety of bullet train maintenance is improved.

Description

Technical Field

[0001] The present invention relates to a motor vehicle bogie, and in particular to an interactive control system and method for motor vehicle bogie replacement equipment based on digital twin. Background Art

[0002] The control interaction of traditional EMU bogie replacement equipment requires constant communication and cooperation between the front commander and the rear operator due to the long distance between the equipment warehouse and the dispatching control room. The rear operator needs to understand the equipment's operating posture and status based on the feedback from the front commander. Often, multiple communications and adjustments are required to complete an action. There is a problem of inconsistent expression of actual operating information and ideal operating information, that is, there is information delay and inconsistency between the operating-end information and the equipment-end information, which makes the EMU bogie replacement operation very cumbersome and inefficient.

[0003] Due to the different body sizes of different models of EMUs, EMU bogie replacement equipment needs to be compatible with a variety of vehicle models and operation modes, but the traditional operation mode is to manually select the vehicle model and operation mode. When performing some operations with high risk factors, it is not fault-tolerant. Once the operation mode is selected incorrectly, it will affect the maintenance efficiency at the least and endanger the safety of the personnel ahead at the worst.

[0004] Trench bogie replacement equipment such as Figure 1 As shown, it is used to replace the bogies of each train section without dismantling the train during the train maintenance. The bogie replacement equipment consists of a double bracket mechanism 1, a track bridge lateral movement mechanism 2, a track bridge 3, an inner track bridge lifting mechanism 4, a locking mechanism 5 and an outer track bridge lifting mechanism 6. The movement actions of the bogie replacement equipment include the train entering the station, the up and down, left and right, and front and back movements of the left and right brackets, the disassembly of the bogie, the lowering of the track bridge, and the pushing of the track bridge to the outer line.

[0005] Digital twin technology, by establishing a connection between physical entities and virtual entities, reflects the changes in physical entity information in real time on the virtual entity, so that the front-line operator can accurately display the results of each step of the EMU bogie replacement equipment in real time on the digital twin, facilitating all-round monitoring of the equipment. Summary of the invention

[0006] Purpose of the invention: In view of the shortcomings in the prior art, the present invention proposes an interactive control system and method for EMU bogie replacement equipment based on digital twin, which optimizes the coordination between the front and rear during the operation of the bogie replacement equipment, simplifies the operation process, and improves the operation efficiency.

[0007] Technical solution: The digital twin-based EMU bogie replacement equipment interactive control system of the present invention includes a pairing module, which determines the physical entity of the EMU bogie replacement equipment and the corresponding virtual entity of the EMU bogie replacement equipment, and determines the conversion relationship based on the physical entity of the EMU bogie replacement equipment and the virtual entity;

[0008] A synchronization module, wherein the synchronization module obtains the motion data of the motor vehicle bogie replacement device, determines the corresponding virtual motion data according to the motion data of the motor vehicle bogie replacement device, and determines the motion posture of the virtual entity of the target and the synchronous motion of the virtual entity and the physical entity according to the virtual motion data;

[0009] The simulation module obtains the current operating posture data of the device's mechanisms and determines the device's simulated motion data based on the operating posture data of each device's mechanisms.

[0010] The interactive control method of the EMU bogie replacement equipment based on digital twin of the present invention is realized by the interactive control system of the EMU bogie replacement equipment based on digital twin, and the control method comprises the following steps:

[0011] (1) determining a physical entity of the EMU bogie replacement equipment and a corresponding virtual entity of the EMU bogie replacement equipment, and determining a conversion relationship based on the physical entity of the EMU bogie replacement equipment and the virtual entity;

[0012] (2) According to the motion data of the virtual entity, the motion posture of the physical entity of the EMU bogie replacement equipment is mapped to the virtual entity of the EMU bogie replacement equipment, and the position and posture of the physical entity of the EMU bogie replacement equipment and the virtual entity of the EMU bogie replacement equipment are synchronized;

[0013] (3) Based on the virtual motion posture of the device, simulate the subsequent operation trajectory of the mechanism.

[0014] Step (1) includes the following process:

[0015] (1.1) Obtaining the physical entity motion posture of the device, and converting the physical entity motion posture of the device into the physical entity motion data of the device;

[0016] (1.2) Convert physical entity motion data into virtual entity motion data.

[0017] In step (1.1), the movement posture of the physical entity includes the parking position of the EMU on the equipment track, the posture of the double-bracket mechanism during operation, the lifting height of the inner and outer line track bridge lifting mechanism, the lateral movement distance of the track bridge lateral movement mechanism, and the extension and retraction position of the locking device of the locking mechanism.

[0018] In step (1.2), for the mechanism powered by a servo motor, the mechanism displacement is calculated by S = (D*π)*(C1 / C2), where S represents the mechanism displacement distance, D represents the gear diameter, C1 represents the total encoder count, and C2 represents the single-turn encoder count. After each interval T, the current mechanism displacement S is used T Compared with the mechanism displacement distance S, if S T -S≠0, it means the mechanism is moving. By comparing If the result is greater than 0, it means that the mechanism is running in the positive direction, otherwise it is running in the negative direction.

[0019] In step (1.2), for the mechanism that collects data through position sensors, position sensors are arranged at the working position and the storage position, and the in-position signals of the position sensors are used to Determine the two states [A, B]: working and stored. A represents the working position arrival signal, and B represents the storage position arrival signal.

[0020] In step (1.2), for the mechanism for collecting data from the displacement sensor, the data collected by the displacement sensor is called.

[0021] Step (2) includes the following process:

[0022] (2.1) The PC device polls downward and sends polling instructions to the PLC device at fixed intervals;

[0023] (2.2) After receiving the polling command, the PLC device packages the posture data of each mechanism and returns it to the PC device;

[0024] (2.3) The PC device processes the collected data and converts the collected data into the displacement matrix of each motion mechanism of the virtual model of the EMU bogie replacement equipment;

[0025] (2.4) Substitute the displacement matrix into the virtual bogie replacement equipment model, and the virtual bogie replacement equipment model realizes the synchronous movement of the virtual entity model and the physical entity according to the movement of the displacement matrix.

[0026] Step (2.3) includes the following process:

[0027] (2.3.1) After receiving the data packet sent by the PLC, the PC device unpacks it and stores the Lint type and bool type data into different databases;

[0028] (2.3.2) The PC device extracts data from the database corresponding to each mechanism and calculates the displacement matrix of the corresponding mechanism;

[0029] Define the current position vector of the mechanism as P = (P x , Py , P z , P w ), where P x is the position of the moving mechanism on the X-axis, P y is the position of the moving mechanism on the Y axis, P z is the position of the moving mechanism on the Z axis, P w Set to 1;

[0030] After the PC device receives the data packet and updates the database information, the displacement of the mechanism is recorded as T, and the inverse matrix T -1 Indicates movement in the opposite direction; T x Represents the displacement of the moving mechanism on the X-axis, T y Represents the displacement of the moving mechanism on the X-axis, T z Represents the displacement of the moving mechanism on the X-axis:

[0031]

[0032] Calculate the displacement matrix of the mechanism that has been displaced. The position of the mechanism after the displacement is P';

[0033]

[0034] Step (3) includes the following process:

[0035] (3.1) Identify the model of the EMU for which the steering gear is disassembled and assembled;

[0036] (3.2) updating the vehicle model information in the virtual space according to the vehicle model being inspected;

[0037] (3.3) When disassembling or assembling a bogie, determine whether the operation type is a dangerous operation;

[0038] (3.4) Perform different actions according to the type of operation;

[0039] (3.5) Lock dangerous operations and read the current operating status of the equipment;

[0040] (3.6) According to the operation instructions of dangerous actions, the virtual model of the EMU bogie replacement equipment simulates the execution of the operation instructions;

[0041] (3.7) After the corresponding virtual mechanism has simulated the dangerous action, a bounding box collision detection is performed between the simulated operating mechanisms to determine the current dangerous action simulation status.

[0042] Working principle: The present invention determines the physical entity of the EMU bogie replacement equipment and the corresponding virtual entity of the EMU bogie replacement equipment, and determines the conversion relationship between the physical entity and the virtual entity based on the EMU bogie replacement equipment; obtains the action data of the EMU bogie replacement equipment, and determines the corresponding virtual motion data according to the action data of the EMU bogie replacement equipment; determines the virtual entity motion trajectory of the target mechanism according to the virtual motion data of the equipment, and the virtual entity realizes synchronous motion with the physical entity; obtains the current operating posture data of each mechanism of the equipment, determines the simulated motion data of the equipment, and determines the simulated motion trajectory of the target mechanism.

[0043] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0044] (1) The interactive control method of the EMU bogie replacement equipment based on digital twin of the present invention includes the virtual-real synchronous movement of physical equipment and virtual equipment, and the simulation of dangerous operation movement, which optimizes the coordination between the front and rear during the operation of the bogie replacement equipment, simplifies the operation process, and improves the operation efficiency.

[0045] (2) The present invention adopts a virtual-real synchronization method for the EMU steering knuckle replacement equipment to synchronize the movement of the physical entity of the equipment with the virtual model of the equipment. Compared with the traditional operation method, the operating status of the equipment can be known more intuitively.

[0046] (3) The present invention performs virtual simulation before the dangerous operation that occurs during the operation of the EMU bogie replacement equipment, and provides early warning of dangerous conditions, thereby improving the safety of the EMU maintenance process.

[0047] (4) The present invention uses digital twin technology to perform real-time motion monitoring and operation prediction simulation, reducing the frequency of unexpected downtime during the maintenance of EMUs. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 Replacement equipment structure diagram for EMU bogies;

[0049] Figure 2 This is a flow chart of the interactive control method of the motor vehicle bogie replacement equipment based on digital twin of the present invention;

[0050] Figure 3 This is a flowchart of the execution of the interactive control method of the motor vehicle bogie replacement equipment based on digital twin of the present invention;

[0051] Figure 4 It is a schematic diagram of the equipment data collection process of the present invention;

[0052] Figure 5 It is a schematic diagram of collision detection of the present invention. DETAILED DESCRIPTION

[0053] The interactive control system of the motor vehicle bogie replacement equipment based on digital twin of the present invention includes:

[0054] A pairing module is used to determine the physical entity of the EMU bogie replacement equipment and the corresponding virtual entity of the EMU bogie replacement equipment, and determine the conversion relationship between the physical entity of the EMU bogie replacement equipment and its virtual entity.

[0055] The synchronization module is used to obtain the action data of the EMU bogie replacement equipment, determine the corresponding virtual motion data according to the EMU bogie replacement equipment action data, determine the virtual entity motion trajectory of the target according to the equipment virtual motion data, and realize the synchronous motion of the virtual entity with the physical entity.

[0056] The simulation module is used to obtain the current operating posture data of each mechanism of the device and determine the device simulation motion data based on the operating posture data of each mechanism of the device.

[0057] like Figure 2 and Figure 3 As shown, the interactive control method of the motor vehicle bogie replacement equipment based on digital twin of the present invention comprises the following steps:

[0058] Step (1) determines the physical entity of the EMU bogie replacement equipment and the corresponding virtual entity of the EMU bogie replacement equipment, and based on the conversion relationship between the physical entity of the EMU bogie replacement equipment and its virtual entity, converts the physical entity motion posture into virtual entity motion data. The specific process is to pair a virtual EMU bogie replacement equipment with the EMU bogie replacement equipment, wherein the EMU bogie replacement equipment is the actual EMU bogie replacement equipment, and the virtual EMU bogie replacement equipment is the EMU bogie replacement equipment model presented on the terminal. Step (1) includes the following steps:

[0059] (1.1) Obtain the physical entity motion posture of the device, and convert the physical entity motion posture of the device into the physical entity motion data of the device.

[0060] Among them, the physical entity motion posture includes:

[0061] a. The parking position of the EMU on the equipment track. During maintenance, the EMU stops on the maintenance equipment track. The parking position and posture of the EMU is the position and posture of the EMU's physical entity on the maintenance equipment track.

[0062] b. The position and posture of the double bracket mechanism during operation. A single bracket is composed of a lateral moving mechanism, an up-down moving mechanism, and a front-to-back moving mechanism. The position and posture of each bracket during operation on the base is determined by the lateral moving mechanism, the up-down moving mechanism, and the front-to-back moving mechanism. Each moving mechanism determines the position of the bracket in each direction, and each moving mechanism is controlled by its own servo motor.

[0063] c. The lifting height of the inner and outer track bridge lifting mechanism. The inner and outer track bridge is lifted and lowered by hydraulic cylinders and slide rails.

[0064] d. Transverse movement distance of the track bridge transverse movement mechanism. The track bridge transverse movement is used to transfer the inner and outer line bogies, and the position of the transverse movement is controlled by the servo motor.

[0065] e. The extended and retracted positions of the locking device of the locking mechanism. The locking mechanism is used to fix the rail bridge at a certain position, and the extension and retraction of the locking device are controlled by the hydraulic cylinder.

[0066] The conversion method of physical entity motion data is the data of the proximity switch, servo motor encoder and displacement sensor on the device node during motion, which is reflected in:

[0067] a. For mechanisms such as double brackets and lateral movement of rail bridges that are driven by servo motors, the counts of the servo motor encoders are used to indirectly reflect the physical entity motion data of the mechanism.

[0068] b. For the physical entity motion data of the movements such as the EMU stopping on the equipment track and the raising and lowering of the inner and outer track bridges, the displacement sensor data installed on the equipment base is directly read, and the distance between the motion mechanism and the base is transformed to reflect the physical entity motion data of the mechanism.

[0069] c. For the physical entity motion data of the locking device of the locking mechanism, the physical entity motion data of the mechanism is reflected by the proximity switch of the extended and retracted positions of the locking device.

[0070] (1.2) Convert the physical entity motion data into virtual entity motion data. The virtual entity motion data of the mechanism includes the virtual mechanism motion displacement and virtual mechanism motion direction. According to the different types of collected data, there are three conversion methods:

[0071] a. For double-bracket and rail bridge lateral movement mechanisms powered by servo motors, the physical entity motion data is indirectly reflected by the counts of the servo motor encoder; the displacement conversion of the physical entity motion data of these mechanisms to virtual entity motion data is calculated by S = (D*π)*(C1 / C2) / K, where S represents the virtual mechanism motion displacement, D represents the gear diameter, C1 represents the total count of the current motion servo motor encoder, C2 represents the single-turn encoder count, and K is the scaling factor for the conversion of physical entity motion data to virtual entity motion data.

[0072] After the movement direction of the physical entity motion data of the above mechanism is converted to the virtual entity motion data at each interval unit time T, the current virtual mechanism displacement S T Compared with the displacement distance S of the historical mechanism, if S T-S≠0, it means the mechanism is moving. By comparing If the result is greater than 0, it means that the mechanism is running in the positive direction, otherwise it is running in the negative direction.

[0073] b. For the physical entity motion data of the locking mechanism, the physical entity motion data of the mechanism is reflected by the proximity switch status of the extended and retracted positions of the locking position. The in-position signal of the proximity switch of the extended and retracted positions indicates the current position of the locking device. The physical locking mechanism has only two states: working and retracted. The virtual locking mechanism is also the same. Distinguish between two states of the virtual locking mechanism (1 represents in place, 0 represents not in place, [1,0] represents the working position in place signal, [0,1] represents the storage position in place signal), the virtual mechanism movement displacement of the locking mechanism is a fixed value, and the virtual mechanism movement direction of the locking mechanism is distinguished according to the working and stored states.

[0074] c. For the physical entity motion data of the train stopping on the equipment track and the lifting and lowering of the inner and outer track bridges, directly read the displacement sensor data S installed on the equipment base W , the distance between the motion mechanism and the base changes to reflect the physical entity motion data of the mechanism; the virtual motion displacement S of the lifting mechanism of the moving vehicle and the inner and outer track bridge is S W / K, where K is the scaling factor for converting physical entity motion data to virtual entity motion data.

[0075] The movement direction of the physical entity motion data of the mechanism is converted to the movement direction of the virtual entity motion data after each unit time T, using the current virtual mechanism displacement S T Compared with the displacement distance S of the historical mechanism, if S T -S≠0, it means that the mechanism is moving. By comparison, if the result is greater than 0, it means that the mechanism is moving in the positive direction, otherwise it is moving in the negative direction.

[0076] Through the above conversion relationship, the physical entity motion posture of the EMU bogie replacement equipment, including the parking position of the EMU on the equipment track, the position of the double-bracket mechanism during operation, the lifting height of the inner and outer track bridge lifting mechanism, the lateral movement distance of the track bridge lateral movement mechanism, and the extension and retraction position of the locking device of the locking mechanism, are converted into the virtual mechanism motion displacement and virtual mechanism motion direction of the virtual EMU bogie replacement equipment.

[0077] Step (2), based on the virtual entity motion data, maps the motion posture of the physical entity of the EMU bogie replacement equipment to the virtual EMU bogie replacement equipment, and synchronizes the position and posture of the physical entity of the EMU bogie replacement equipment and the virtual entity of the EMU bogie replacement equipment.

[0078] In actual applications, the physical EMU bogie replacement equipment is equipped with a controller, which is the programmable logic controller (PLC) device on the EMU bogie replacement equipment. The PLC device is connected to the servo motor, displacement sensor, proximity switch, and hydraulic cylinder controller on the physical EMU bogie replacement equipment node, and serves as the lower computer of the physical EMU bogie replacement equipment; the virtual EMU bogie replacement equipment is also equipped with a controller, which is a PC device serving as a terminal. The PC device serves as a host computer and is used to display the model of the virtual EMU bogie replacement equipment and convert the virtual entity motion data into the motion posture of the virtual EMU bogie replacement equipment.

[0079] After the conversion, the virtual entity motion data is saved in the PLC internal register. The action data storage types are mainly bool type and Lint type. Bool type is used to save the virtual entity motion data of the locking mechanism; Lint type is used to save the virtual entity motion data of the double bracket, the lateral movement of the track bridge, the parking of the motor vehicle on the equipment track, and the lifting of the inner and outer track bridge. Step (2) includes the following process:

[0080] (2.1) The PC device polls downward and sends polling instructions to the PLC device at fixed intervals. The physical entity is the actual EMU bogie replacement equipment, and the virtual entity is the virtual EMU bogie replacement equipment based on digital twins established on the PC device. Data is exchanged between the two locations via optical fiber. When the trench bogie replacement equipment is operating, the PC device sends polling commands to the devices in the device library at very short intervals. The polling commands include access to data in digital input registers, high-speed pulse data registers, and file registers.

[0081] (2.2) After receiving the polling command, the PLC device packages the position data of each mechanism into a data packet and returns it to the PC device. The specific process is that after receiving the polling command, the PLC device packages the virtual entity motion data of each mechanism of the EMU bogie replacement equipment into a data packet. Each data packet consists of real-time periodic data and real-time non-periodic data.

[0082] Real-time periodic data includes monitoring data and process data. Monitoring data is used to reflect management information, and process data is generated by various parts of the equipment when it is running, and it provides status monitoring information of the feedback mechanism. This type of data is periodic and has high real-time requirements.

[0083] Real-time non-periodic data includes message data and stream data, specifically, device alarm signals and emergency instructions. After the data packet is packaged, it is sent to the PC device in the form of a data frame. The data frame follows the data frame structure requirements defined by IEE802.1Q. In the VLAN field of the data frame, the sent data is divided into 8 different priorities, and the corresponding data is sorted according to importance, and important data is read first.

[0084] (2.3) The PC device processes the collected data and converts the collected different data into the displacement matrix of each motion mechanism of the virtual model of the EMU bogie replacement equipment. Step (2.3) includes the following processes:

[0085] (2.3.1) After receiving the data packet sent by the PLC, the PC device will unpack it and store the Lint type and bool type data into different databases.

[0086] (2.3.2) The PC device extracts data from the database corresponding to each mechanism and calculates the displacement matrix of the corresponding mechanism;

[0087] The process of calculating the displacement matrix is ​​as follows: for the mechanism that has undergone displacement, such as the extended bracket when the double bracket mechanism is operating, the motor vehicle when it is parked and driven out on the equipment track, the track bridge when the inner and outer line track bridge lifting mechanism is lifting, the track bridge when the track bridge lateral movement mechanism is lateral movement, and the locking device when the locking device is extended and retracted, define the current position vector of the mechanism as P = (P x , P y , P z , P w ), where P x is the position of the moving mechanism on the X-axis, P y is the position of the moving mechanism on the Y axis, P z is the position of the moving mechanism on the Z axis, P w Set to 1 to use the homogeneous method to express the current position vector P of the mechanism as a moving point relative to the origin in the three-dimensional coordinate system.

[0088] The PC device receives the data packet, unpacks it and updates the database information. The displacement of the mechanism after the information is updated is recorded as T, and its inverse matrix T -1 Indicates movement in the opposite direction; T x Represents the displacement of the moving mechanism on the X-axis, T y Represents the displacement of the moving mechanism on the X-axis, T z Represents the displacement of the moving mechanism on the X-axis.

[0089]

[0090] Calculate the displacement matrix of the mechanism that has been displaced. The position of the mechanism after the displacement is P';

[0091]

[0092] (2.4) Substitute the calculated displacement matrix into the virtual bogie replacement equipment model. The virtual bogie replacement equipment model moves according to the displacement matrix to achieve synchronous movement of the virtual entity model and the physical entity, that is, the running posture of the virtual mechanism will be synchronized with the running posture of the physical mechanism of the physical bogie replacement equipment. Among them, this synchronization state is bidirectional, that is, the movement of the physical mechanism of the physical bogie replacement equipment is reflected in the virtual bogie replacement equipment model; when the corresponding virtual mechanism on the virtual bogie replacement equipment model is displaced, the result of the virtual mechanism displacement will also be reflected in the physical mechanism corresponding to the physical bogie replacement equipment.

[0093] The bidirectionality of the synchronization state is determined by the properties of the PLC device register. When the register has the readable and writable properties enabled, the synchronization state is bidirectional; when only the readable property is enabled, the synchronization state only realizes the movement of the physical mechanism of the physical bogie replacement device, which will be reflected in the virtual bogie replacement device model.

[0094] Step (3), according to the virtual motion posture of the equipment, simulate the subsequent running trajectory of the mechanism. In actual operation, due to the different sizes of the EMU body of different models, the EMU bogie replacement equipment is compatible with a variety of vehicle operation modes, but the traditional operation mode is to manually select the operation mode according to the vehicle model. Different operation modes involve the different positions of certain motion mechanisms of the EMU bogie replacement equipment during operation, including the bracket mechanism and the inner and outer track bridge lifting mechanism. When performing these operations with high risk factors, it does not have fault tolerance. Once the operation position of the mechanism is selected incorrectly during the operation mode, it will affect the maintenance efficiency at the least and endanger the safety of the personnel in front at the worst. In this regard, the interactive control method of the present invention includes a simulation operation strategy, which obtains the current operating state of the bogie replacement equipment based on the captured EMU picture information, the body position information, and the current posture information of the bogie mechanism, and simulates the subsequent operating state based on the current operating state, and displays it to the equipment operator through the terminal window for alarm and reminder.

[0095] Among them, the same type of EMU bogie replacement equipment can meet the disassembly and maintenance operations of various models, that is, different operation modes are matched according to different models. The different operation modes include: the parking distance of carriages of different models when the train stops, different bracket lifting heights, different bracket extension lengths, different track bridge descending speeds and different track bridge removal speeds.

[0096] According to the equipment action data of the EMU bogie replacement, determine the next movement data of the current moving mechanism of the equipment, and reflect the simulated action in the virtual model, collect the equipment movement mechanism posture data and vehicle model data, and simulate the next action of the moving mechanism of the equipment according to the equipment movement mechanism posture data and vehicle model data. Step (3) includes the following steps:

[0097] Step (3.1) performs model identification on the EMU that is undergoing bogie disassembly and assembly. When different models of vehicles enter the EMU bogie replacement equipment, the camera above the track collects images of the train. The captured images are put into the vehicle model identification model, which is a multi-layer convolutional neural network model that determines the vehicle model based on the body shape information and body color pattern information.

[0098] Step (3.2) updates the vehicle model information in the virtual space according to the model of the vehicle being repaired. Updates the body model data of the virtual model in the digital twin system according to the train model on the current physical bogie replacement device. The virtual models of different vehicle models not only have different body paint and body sizes, which facilitates operators to judge different vehicle models; but also have different collision volumes at the locations where different mechanisms of the equipment come into contact, and at the virtual models of different vehicle models, which are used to simulate the feedback of different vehicle models in different operating modes during movement.

[0099] Step (3.3) performs the bogie disassembly and assembly operation. Before executing each step, it is determined whether the operation type is a dangerous operation. When the device is in operation, it contains dangerous operation commands, such as the process of the bracket lifting the car body and the process of the track bridge moving horizontally out. The present invention includes a dangerous action library to distinguish whether the current operation command is a dangerous operation.

[0100] Step (3.4), according to the type of operation behavior, different actions are performed. After comparing the current operation with the operations in the dangerous action library, if the current operation is not in the dangerous action library, the current operation command is directly executed, and the EMU bogie replacement device performs the action. If the current operation is in the dangerous action library, because this operation is a dangerous operation, the EMU bogie replacement device locks the operation of the current command to prevent erroneous execution.

[0101] Step (3.5), when encountering dangerous operation, lock the operation, and after the operation is locked, read the current operating status of the equipment. After locking the operation of the current instruction, in order to prevent the error between the virtual model of the EMU bogie replacement equipment and the physical vehicle bogie replacement equipment synchronization state, the PC host computer immediately reads the data in the PLC device register of the slave computer and updates the virtual model.

[0102] Step (3.6), according to the operation instruction of the dangerous action, the virtual model of the EMU bogie replacement equipment simulates the execution of the operation instruction.

[0103] Step (3.7), after the corresponding virtual mechanism simulates the dangerous action, the bounding box collision detection between the simulated operating mechanisms is performed to determine whether the current dangerous action simulation state has passed. If the bounding box collision detection result shows a dangerous action.

[0104] Among them, the contact positions of each mechanism of the virtual equipment model and the virtual models of different car models are all set with different collision volumes. After the virtual mechanism of the equipment moves to the position according to the operation instruction, the system performs Boolean operations to obtain the status between the virtual motion mechanism and the mechanism near the target position of the virtual motion mechanism. The status includes collision, collision, and collision maintenance. According to the status, it is judged whether there is a collision, scratch, or the working mechanism is not in place between the mechanisms. According to the problem, the PC device issues a warning and reminder. At this time, check the instruction, and correct the error in the instruction, and the device continues to run.

[0105] As a preferred method, X86-based PC devices and handheld devices are used to remotely view the status and control the posture of the EMU bogie replacement equipment in an industrial Internet of Things environment, providing intuitive and real-time feedback on the equipment operation to the operators.

Claims

1. An interactive control system for EMU bogie replacement equipment based on digital twin, characterized by: It includes a pairing module, which determines a physical entity of a motor vehicle bogie replacement device and a corresponding virtual entity of the motor vehicle bogie replacement device, and determines a conversion relationship based on the physical entity of the motor vehicle bogie replacement device and the virtual entity; A synchronization module, wherein the synchronization module obtains the motion data of the motor vehicle bogie replacement device, determines the corresponding virtual motion data according to the motion data of the motor vehicle bogie replacement device, and determines the motion posture of the virtual entity of the target and the synchronous motion of the virtual entity and the physical entity according to the virtual motion data; The simulation module obtains the current operating posture data of the device's mechanisms and determines the device's simulated motion data based on the operating posture data of each device's mechanisms.

2. An interactive control method for EMU bogie replacement equipment based on digital twin, characterized in that: The interactive control system for the EMU bogie replacement equipment based on digital twin according to claim 1 is implemented, and the interactive control method comprises the following steps: (1) determining a physical entity of the EMU bogie replacement equipment and a corresponding virtual entity of the EMU bogie replacement equipment, and determining a conversion relationship based on the physical entity of the EMU bogie replacement equipment and the virtual entity; (2) According to the motion data of the virtual entity, the motion posture of the physical entity of the EMU bogie replacement equipment is mapped to the virtual entity of the EMU bogie replacement equipment, and the position and posture of the physical entity of the EMU bogie replacement equipment and the virtual entity of the EMU bogie replacement equipment are synchronized; (3) Based on the virtual motion posture of the device, simulate the subsequent operation trajectory of the mechanism.

3. The interactive control method for replacing motor vehicle bogies based on digital twin according to claim 2 is characterized in that: Step (1) includes the following process: (1.1) Obtaining the physical entity motion posture of the device, and converting the physical entity motion posture of the device into the physical entity motion data of the device; (1.2) Convert physical entity motion data into virtual entity motion data.

4. The interactive control method for replacing a motor vehicle bogie based on digital twin according to claim 3 is characterized in that: In step (1.1), the movement posture of the physical entity includes the parking position of the motor vehicle on the equipment track, the posture of the double-bracket mechanism during operation, the lifting height of the inner and outer line track bridge lifting mechanism, the lateral movement distance of the track bridge lateral movement mechanism, and the extension and retraction position of the locking device of the locking mechanism.

5. The interactive control method for replacing motor vehicle bogies based on digital twin according to claim 3 is characterized in that: In step (1.2), for the mechanism powered by a servo motor, the mechanism displacement is calculated by S = (D*π)*(C1 / C2), where S represents the mechanism displacement distance, D represents the gear diameter, C1 represents the total encoder count, and C2 represents the single-turn encoder count. After each interval T, the current mechanism displacement S is used T Compared with the mechanism displacement distance S, if S T -S≠0, it means the mechanism is moving. By comparing If the result is greater than 0, it means that the mechanism is running in the positive direction, otherwise it is running in the negative direction.

6. The interactive control method for replacing motor vehicle bogies based on digital twin according to claim 3 is characterized in that: In step (1.2), for the mechanism that collects data through position sensors, position sensors are arranged at the working position and the storage position, and the in-position signals of the position sensors are used to Determine the two states [A, B]: working and stored. A represents the working position arrival signal, and B represents the storage position arrival signal.

7. The interactive control method for replacing motor vehicle bogies based on digital twin according to claim 3 is characterized in that: In step (1.2), for the mechanism for collecting data from the displacement sensor, the data collected by the displacement sensor is called.

8. The interactive control method for replacing motor vehicle bogies based on digital twin according to claim 2 is characterized in that: Step (2) includes the following process: (2.1) The PC device polls downward and sends polling instructions to the PLC device at fixed intervals; (2.2) After receiving the polling command, the PLC device packages the posture data of each mechanism and returns it to the PC device; (2.3) The PC device processes the collected data and converts the collected data into the displacement matrix of each motion mechanism of the virtual model of the EMU bogie replacement equipment; (2.4) Substitute the displacement matrix into the virtual bogie replacement equipment model, and the virtual bogie replacement equipment model realizes the synchronous movement of the virtual entity model and the physical entity according to the movement of the displacement matrix.

9. The interactive control method for motor vehicle bogie replacement equipment based on digital twin according to claim 8 is characterized in that: Step (2.3) includes the following process: (2.3.1) After receiving the data packet sent by the PLC, the PC device unpacks it and stores the Lint type and bool type data into different databases; (2.3.2) The PC device extracts data from the database corresponding to each mechanism and calculates the displacement matrix of the corresponding mechanism; Define the current position vector of the mechanism as P = (P x , P y , P z , P w ), where P x is the position of the moving mechanism on the X-axis, P y is the position of the moving mechanism on the Y axis, P z is the position of the moving mechanism on the Z axis, P w Set to 1; After the PC device receives the data packet and updates the database information, the displacement of the mechanism is recorded as T, and the inverse matrix T -1 Indicates movement in the opposite direction; T x Represents the displacement of the moving mechanism on the X-axis, T y Represents the displacement of the moving mechanism on the X-axis, T z Represents the displacement of the moving mechanism on the X-axis: Calculate the displacement matrix of the mechanism that has been displaced. The position of the mechanism after the displacement is P'; 10. The interactive control method for replacing motor vehicle bogies based on digital twin according to claim 2 is characterized in that: Step (3) includes the following process: (3.1) Identify the model of the EMU for which the steering gear is disassembled and assembled; (3.2) updating the vehicle model information in the virtual space according to the vehicle model being inspected; (3.3) When disassembling or assembling a bogie, determine whether the operation type is a dangerous operation; (3.4) Perform different actions according to the type of operation; (3.5) Lock dangerous operations and read the current operating status of the equipment; (3.6) According to the operation instructions of dangerous actions, the virtual model of the EMU bogie replacement equipment simulates the execution of the operation instructions; (3.7) After the corresponding virtual mechanism has simulated the dangerous action, a bounding box collision detection is performed between the simulated operating mechanisms to determine the current dangerous action simulation status.

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