Automobile hub intelligent manufacturing production line construction method and system based on digital twinning

Abstract

The invention discloses an automobile hub intelligent manufacturing production line construction method and system based on digital twinning, and relates to the technical field of industrial internet and digital twinning, and the production line construction method comprises the following steps: carrying out the two-dimensional plane layout design of an automobile hub manufacturing physical production line; according to the automobile hub production system based on digital twinning, modeling is conducted on three-dimensional geometric attributes and physical attributes of a production unit of an automobile hub manufacturing physical production line, digital twinning simulation software is imported into three models of the production unit of the automobile hub manufacturing physical production line, and a digital twinning line layout is completed. The digital twin system of the intelligent automobile hub manufacturing production line is constructed by taking automobile hub machining, grinding and detecting procedures as a main line, digitalization, intelligentization, networking and visualization of automobile hub production are realized, and the production efficiency and the management and control capability of automobile hub manufacturing enterprises are improved through the functions of monitoring, prediction, analysis, diagnosis and the like, so that the production efficiency and the management and control capability of the automobile hub manufacturing enterprises are improved. And intelligent manufacturing of the automobile hub is achieved.

Description

Technical Field

[0001] The present invention relates to the field of industrial Internet and digital twin technology, and specifically to a method and system for constructing an automobile wheel hub intelligent manufacturing production line based on digital twin. Background Art

[0002] With the integration and development of advanced technologies such as artificial intelligence, industrial Internet of Things, and digital twins in the manufacturing field, a new round of industrial revolution has been promoted. Intelligent manufacturing has become the main direction of development of the manufacturing industry. Traditional digital production lines have long on-site debugging cycles, poor interaction between physical production line entities and virtual three-dimensional models, poor visualization capabilities, high on-site status monitoring costs, weak data transmission capabilities, and asynchronous production data. It is difficult to achieve real-time visualization and remote management of production line information.

[0003] In recent years, as an emerging technology, digital twin technology has broken the barriers that hinder the interaction between physical space and information space, and provided technical support for the realization of digitalization, intelligence and networking of production lines. As one of the important solutions to realize the interaction between physical entities and virtual space, digital twin technology provides a reference for the design and implementation of intelligent production lines. The research and application of digital twin technology in the field of intelligent manufacturing have attracted more and more attention from relevant researchers at home and abroad. Tao Fei and others from Beijing University of Aeronautics and Astronautics first proposed the concept of digital twin workshop, and elaborated on the composition, characteristics, operation mechanism and key technologies of digital twin workshop system. In terms of the construction and application of digital twin system, Wei Yixiong and others built a high-fidelity mapping digital twin workshop simulation environment, and adopted a data collection method based on the Open Production Control and Unified Architecture (OPC UA) server to realize real-time mirroring of physical entities. Qiu Xiaoli and others used OpenInventor software to improve the fidelity of twin models by mapping the movement mode, constraint relationship and other laws of physical objects. Deac GC and others developed a collaborative virtual reality application based on factory digital twins as an interface for monitoring big data, and synchronized the movement of virtual machines with real machines. Jiang Zhichao and others used Process The Simulate software established a virtual debugging module for the supercapacitor module testing line, which enabled the debugging and optimization of the programmable logic controller program and the robot program before they were applied to the physical equipment.

[0004] Digital twins are essentially simulations. Various solutions can be tested through digital twin simulations. Introducing digital twin technology into smart manufacturing production lines and building digital twin smart production lines that synchronize the real and virtual can effectively solve the complex and uncertain problems that arise in the manufacturing process. In addition, smart manufacturing production lines based on digital twin technology can complete the model design, layout, robot offline programming and other processes of each unit in the production line in a virtual environment, which is both safe and greatly reduces the R&D and debugging time and cost of the production line.

[0005] The automobile wheel hub is the core part that supports the tire to be installed on the central axis. With the popularization and application of automobiles, the demand for wheels is huge. At the same time, with the intensified competition among wheel hub manufacturers and the rapid iteration of products, the production of wheel hubs is shifting towards personalization, diversification and complexity. The traditional production and processing is that the operator puts the semi-finished casting blanks on the machine tool for cutting, grinding and other processes to remove the risers, burrs and other excess parts generated during the casting of the wheel hub so that the workpiece meets the requirements of the wheel hub assembly. The production of automobile wheels through traditional production lines mainly has the following problems: First, the working environment is poor, the process time is long, and the work efficiency is low; second, the wheel hub needs to be ground during processing, which is easy to form aluminum alloy dust, which may lead to the potential risk of dust explosion; third, the production line processing process has poor visualization capabilities, high on-site status monitoring costs, weak data transmission capabilities, and asynchronous production data. Problems such as these make it difficult to achieve real-time visualization and remote management of production line information. Summary of the invention

[0006] The purpose of the present invention is to provide a method and system for constructing an automobile wheel hub intelligent manufacturing production line based on digital twins to solve the problems raised in the above background technology.

[0007] To achieve the above object, the present invention provides the following technical solution: a method for constructing an automobile wheel hub intelligent manufacturing production line based on digital twin, comprising the following steps:

[0008] S1, simulates the 2D layout of the physical production line for automobile wheel manufacturing;

[0009] S2, based on the two-dimensional plane layout of the physical production line of automobile wheel hub manufacturing, combined with the geometric properties and physical properties of the physical production line, construct a three-dimensional model of the physical production line of automobile wheel hub manufacturing;

[0010] S3, importing the three-dimensional model of the automobile wheel hub manufacturing production line in step S2 into the digital twin simulation software, and completing the digital twin production line layout;

[0011] S4, behavioral attribute modeling for the digital twin production line;

[0012] S5, logical attribute modeling for the digital twin production line;

[0013] S6, data communication modeling for digital twin production lines;

[0014] S7, edit drive scripts for digital twin production lines;

[0015] Among them, in the above step S1, the automobile wheel hub manufacturing physical production line includes an execution unit, a tool unit, a processing unit, a detection unit, a sorting unit, a storage unit, a general control unit and a production line environment; the two-dimensional plane layout is: the execution unit is arranged in the center of the factory, the tool unit and the processing unit are arranged on the north side of the execution unit; the sorting unit and the detection unit are arranged on the south side of the execution unit; the storage unit is arranged on the west side of the execution unit; the general control unit is arranged on the east side of the execution unit; the execution unit intelligent control rail realizes the coordination of taking and putting workpieces or tools of each production unit;

[0016] Wherein, in the above step S2, the three-dimensional modeling of each production unit of the physical production line of automobile wheel hub manufacturing includes execution unit modeling, tool unit modeling, processing unit modeling, detection unit modeling, sorting unit modeling, storage unit modeling, general control unit modeling, production line environment modeling and personnel modeling; the geometric attributes include the shape, size, position relationship and assembly relationship of the equipment; the physical attributes include the specific material, quality, rigidity, strength, speed and acceleration of each equipment unit component, and the geometric attribute and physical attribute information of each equipment unit are imported into the three-dimensional software for construction, wherein the three-dimensional software adopts UG or CATIA, and is saved as an STL format file;

[0017] Among them, in the above step S3, the three-dimensional model files constructed in step 2 are sequentially imported into the digital twin simulation software, the digital twin simulation software adopts PQfactory, and the digital twin accurate mapping layout of the physical production line is completed in the digital twin simulation software, so as to realize the intuitive display of the automobile wheel hub intelligent manufacturing production line in a visual form in the digital twin software;

[0018] Wherein, in the above step S4, the behavior attribute modeling includes modeling of the mutual drive between various production units of automobile wheel hub manufacturing, the connection signals between equipment, the action scripts and the data statistics;

[0019] Wherein, in the above step S5, the logic attribute modeling includes modeling the motion coordinates, motion range, motion relationship, and motion variables of each production unit component or joint of the automobile wheel hub manufacturing;

[0020] In the above step S6, the data communication modeling is to allocate IP addresses to each production unit to achieve linkage between models for production process simulation and physical entity mapping; data interaction interface modeling and virtual communication interface modeling between digital models of each production unit;

[0021] Among them, in the above step S7, the script editing refers to connecting the various attributes and communication interfaces of the device model through a connection script, driving the movement of the twin model in a script manner, thereby realizing the construction of the device twin model; through the established twin model driving scripts and communication interfaces of each production equipment, testing is carried out in the digital twin virtual environment, and real-time data interaction between device twin models is realized through the virtual-real communication interface, thereby driving the operation of the twin model to verify whether the digital twin model conforms to the processing, detection, transmission, and sorting actions and functions of each unit of the physical production line, and finally realizing the construction and verification of the entire digital twin production line system.

[0022] It also includes joint debugging of the intelligent production line of automobile wheels and the digital twin system, and simulation optimization; connecting the various production unit modules through the network, and docking with the digital twin simulation system platform by writing PLC programs to verify the functional realization of each production unit and perform optimization debugging;

[0023] The joint debugging and simulation optimization includes the following process steps:

[0024] S8-1,PLC programming;

[0025] S8-2, define signal;

[0026] S8-3, trajectory making;

[0027] S8-4, address matching;

[0028] S8-5, industrial robot program editing;

[0029] S8-6,PLC program debugging;

[0030] S8-7, process verification.

[0031] An automobile wheel hub intelligent manufacturing production line system based on digital twins, the system includes a physical production line layer, a data layer, a digital twin production line layer and an application service layer; by constructing a mapping between the various production elements of the actual automobile wheel hub production line, that is, a full-scale perception of the production line's people, machines, materials and environment, the physical production line layer includes an execution unit, a processing unit, a storage unit, a transmission unit and a detection unit. The geometric properties, physical properties, behavioral properties, motion logic and data communication of multiple modules are fully mapped, and the properties of the physical production line of the automobile wheel hub intelligent manufacturing are connected with the digital twin production line through a driving script to complete the construction of the digital twin model of each production unit; finally, a high degree of consistency between the twin model of each production equipment and the actual equipment in terms of geometry, physics, behavior and logic of production elements is established.

[0032] The physical production line layer is the data source for modeling the three-dimensional model of the digital twin production line and production and processing information; the physical production line of intelligent manufacturing of automobile wheel hubs includes a physical equipment module and a data perception module. The physical equipment module includes an execution unit, a processing unit, a tool unit, a sorting unit, a grinding unit, a detection unit, a storage unit, a general control unit, and multiple staff elements; the data perception module includes multiple elements such as various sensors, programmable logic controllers, industrial computers, motion controllers, and network infrastructure. Its function is to collect basic parameters, material information, operating data, and environmental status data of physical equipment, and provide a communication link for the host computer software to send commands to various types of equipment, collect data instructions, and interact with data transmission. It is the support for controlling the signal transmission and orderly processing of each device, and provides an interface with the data layer to provide a data source for the information service layer. The organic combination of the physical equipment module and the perception module realizes the orderly and coordinated operation of each device in the physical production line layer.

[0033] The data layer guides the completion of data collection, transmission, integration, analysis and driving. Its function is to realize the interconnection of various parts of the system and ensure the stable operation of the system. The twin data of the data layer includes real-time data generated by the physical production line, as well as related data generated by the digital twin model and application service system. The data layer uploads and stores the data collected from the physical entity layer on the server, and part of the data flows into the digital twin production line layer as the data source for driving the twin model. The other part of the data is used for the service layer to provide big data statistical analysis support for the application service layer, so as to realize data visualization, status monitoring and fault diagnosis of the application service layer.

[0034] The data layer uses S7, OPC UA, Modbus TCP, ProfiNet, and DeviceNet multi-source heterogeneous data acquisition methods to collect data, respectively realizing the collection requirements of multiple production data of the execution unit, processing unit, detection unit, and storage unit; an OPC UA server is built through third-party software and data acquisition cards to complete data collection, and the built OPC UA server is connected to the OPC UA client in the digital twin production line to form a data transmission bridge, so that the collected data structure is unified and standardized, and data transmission and interaction are realized in the digital twin production line layer and application service layer.

[0035] The digital twin production line layer is based on the three-dimensional modeling technology to accurately map the entities of the physical production line layer in the virtual space, and conducts comprehensive digital modeling of the geometric models, assembly constraints, color materials, behavioral attributes, logical attributes and data interfaces of each production factor of the physical production line layer to build a digital twin production line that is highly realistic with the physical production line; the digital twin production line layer uses the data collected by the physical production line entity layer and uses logic scripts to drive the twin model in real time, reproduce the physical production line processing actions, signal transmission and control multiple attributes in the digital twin production line system, and provide real-time feedback on the dynamic and static characteristics of the physical production line.

[0036] The application service layer includes data visualization, workshop information management system, Internet of Things platform and database; the information service layer is the basis for realizing online simulation, monitoring, evaluation, optimization, prediction and decision-making of the whole process, all elements and the whole flow of the workshop; users interact with the digital twin system through the application service layer to realize three-dimensional visualization monitoring of the production line equipment status and product status in all elements and the whole process, and open up the information flow and data flow of the entire digital twin system; by analyzing, storing and optimizing the data obtained from the physical production line and the digital twin production line, the data is introduced into multiple workshop information management systems such as enterprise resource planning, manufacturing execution system, product data management and warehouse management system, and the data is integrated, analyzed and iteratively optimized in the workshop information management system, and fed back to the digital twin production line system for verification.

[0037] Compared with the prior art, the present invention has the following beneficial effects:

[0038] By simulating the automobile wheel manufacturing process and identifying potential bottlenecks and inefficiencies, the present invention enables wheel manufacturers to optimize their operations to improve productivity and reduce waste. Digital twin technology can be used to monitor the performance of automobile wheel production equipment and detect potential problems before they cause downtime or expensive repairs, enabling wheel manufacturers to proactively schedule maintenance activities. By real-time monitoring of wheel production equipment and its performance during the production process, manufacturers can detect defects and anomalies early in the production process, thereby reducing the likelihood of defects in finished products. By identifying opportunities for optimization and waste reduction, wheel manufacturers can save material, energy and labor costs.

[0039] The present invention combines digital twin technology, takes the automobile wheel hub intelligent manufacturing production line as a carrier, takes the realization of automobile wheel hub intelligent manufacturing as a goal, and proposes an automobile wheel hub production system and construction method solution based on digital twin. CATIA, PQfactory, TIAPortal and other software are used to build a digital twin system of the automobile wheel hub intelligent manufacturing production line. According to the system communication and data acquisition architecture, communication technologies such as OPC UA and Modbus are used to read the real-time data of the production line equipment, and drive the synchronous operation of the digital twin model of the production line, thereby realizing the real-time mapping of the virtual production line to the physical production line. In addition, through the monitoring, prediction, analysis and diagnosis functions of the digital twin system, the production efficiency and management and control capabilities of automobile wheel hub manufacturers can be improved, providing a reference case for the application of digital twin technology in the field of automobile wheel hub intelligent manufacturing production. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 is a flow chart of the method of the present invention;

[0041] Figure 2 It is a two-dimensional plan layout diagram of the present invention;

[0042] Figure 3 It is the overall framework diagram of the present invention;

[0043] Figure 4 A modeling hierarchy diagram for the present invention;

[0044] Figure 5 A schematic diagram of the device modeling structure of the present invention;

[0045] Figure 6 It is the system joint debugging and simulation process of the present invention;

[0046] Figure 7 A schematic diagram of constructing a digital twin model of an industrial robot of the present invention;

[0047] Figure 8 A schematic diagram of constructing a digital twin model of a machining center according to the present invention. DETAILED DESCRIPTION

[0048] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0049] Example 1: Please refer to Figure 1-Figure 8 The present invention provides a method for constructing an automobile wheel hub intelligent manufacturing production line based on digital twin, comprising the following steps:

[0050] S1, simulates the 2D layout of the physical production line for automobile wheel manufacturing;

[0051] S2, based on the two-dimensional plane layout of the physical production line of automobile wheel hub manufacturing, combined with the geometric properties and physical properties of the physical production line, construct a three-dimensional model of the physical production line of automobile wheel hub manufacturing;

[0052] S3, importing the three-dimensional model of the automobile wheel hub manufacturing production line in step S2 into the digital twin simulation software, and completing the digital twin production line layout;

[0053] S4, behavioral attribute modeling for the digital twin production line;

[0054] S5, logical attribute modeling for the digital twin production line;

[0055] S6, data communication modeling for digital twin production lines;

[0056] S7, edit drive scripts for digital twin production lines;

[0057] Among them, in the above step S1, the physical production line of automobile wheel hub manufacturing includes an execution unit, a tool unit, a processing unit, a detection unit, a sorting unit, a storage unit, a general control unit and a production line environment; the two-dimensional plane layout is: the execution unit is arranged in the center of the factory, the tool unit and the processing unit are arranged on the north side of the execution unit; the sorting unit and the detection unit are arranged on the south side of the execution unit; the storage unit is arranged on the west side of the execution unit; the general control unit is arranged on the east side of the execution unit; the intelligent control rail of the execution unit realizes the coordination of taking and putting workpieces or tools of each production unit;

[0058] Among them, in the above step S2, the three-dimensional modeling of each production unit of the physical production line of automobile wheel hub manufacturing includes execution unit modeling, tool unit modeling, processing unit modeling, detection unit modeling, sorting unit modeling, storage unit modeling, general control unit modeling, production line environment modeling and personnel modeling; the geometric attributes include the shape, size, position relationship and assembly relationship of the equipment; the physical attributes include the specific material, quality, rigidity, strength, speed and acceleration of each equipment unit component, and the geometric attribute and physical attribute information of each equipment unit are imported into the three-dimensional software for construction, wherein the three-dimensional software adopts UG or CATIA, and is saved as an STL format file;

[0059] Among them, in the above step S3, the three-dimensional model files constructed in step 2 are sequentially imported into the digital twin simulation software, the digital twin simulation software adopts PQfactory, and the digital twin accurate mapping layout of the physical production line is completed in the digital twin simulation software, so as to realize the intuitive display of the automobile wheel hub intelligent manufacturing production line in a visual form in the digital twin software;

[0060] Wherein, in the above step S4, the behavior attribute modeling includes the modeling of the mutual drive between various production units of automobile wheel hub manufacturing, the connection signals between equipment, the action scripts and the data statistics;

[0061] In the above step S5, the logical attribute modeling includes modeling the motion coordinates, motion range, motion relationship, and motion variables of each production unit component or joint of the automobile wheel hub manufacturing;

[0062] In the above step S6, data communication modeling is to allocate IP addresses to each production unit to achieve linkage between models for production process simulation and physical entity mapping; data interaction interface modeling and virtual communication interface modeling between digital models of each production unit;

[0063] Among them, in the above step S7, script editing refers to connecting various attributes and communication interfaces of the equipment model through connection scripts, driving the movement of the twin model in a scripted manner, thereby realizing the construction of the equipment twin model; through the established twin model driving scripts and communication interfaces of each production equipment, testing is performed in the digital twin virtual environment, and real-time data interaction between equipment twin models is realized through the virtual-real communication interface, thereby driving the operation of the twin model to verify whether the digital twin model conforms to the processing, detection, transmission, and sorting multiple action behaviors and functions of each unit of the physical production line, and finally realizing the construction and verification of the entire digital twin production line system;

[0064] It also includes joint debugging of the intelligent production line of automobile wheels and the digital twin system, and simulation optimization; connecting the various production unit modules through the network, and docking with the digital twin simulation system platform by writing PLC programs to verify the functional realization of each production unit and perform optimization debugging;

[0065] Joint debugging and simulation optimization includes the following process steps:

[0066] S8-1,PLC programming;

[0067] S8-2, define signal;

[0068] S8-3, trajectory making;

[0069] S8-4, address matching;

[0070] S8-5, industrial robot program editing;

[0071] S8-6,PLC program debugging;

[0072] S8-7, process verification.

[0073] The specific implementation of this embodiment is as follows:

[0074] like Figure 2 As shown, in the above step 1, the physical production line of automobile wheel hub manufacturing includes an execution unit, a tool unit, a processing unit, a detection unit, a sorting unit, a storage unit, a general control unit, and a production line environment; the two-dimensional plane layout is that the execution unit is arranged in the center of the factory, the tool unit and the processing unit are arranged on the north side of the execution unit; the sorting unit and the detection unit are arranged on the south side of the execution unit; the storage unit is arranged on the west side of the execution unit; the general control unit is arranged on the east side of the execution unit; the industrial robot of the execution unit realizes the coordination of taking and placing workpieces or tools of each unit through the guide rail;

[0075] like Figure 4 As shown, in the above step 2, the three-dimensional geometric attributes and physical attributes modeling of the production unit of the physical production line of automobile wheel hub manufacturing include execution unit modeling, tool unit modeling, processing unit modeling, detection unit modeling, sorting unit modeling, storage unit modeling, general control unit modeling, production line environment modeling, and personnel modeling; Figure 5 As shown, the geometric properties include the shape, size, positional relationship and assembly relationship of the equipment, and the physical properties include the specific material, mass, rigidity, strength, speed and acceleration of each equipment unit component. According to the specific geometric properties and physical property information of each equipment unit, it is constructed in 3D software (UG, CATIA) and saved as an STL format file;

[0076] In the above step 3, the three models of the production unit of the automobile wheel hub manufacturing production line are imported into the digital twin simulation software and the layout of the digital twin production line is completed, which means that the three-dimensional model files constructed in step 2 are sequentially imported into the digital twin simulation software (such as PQfactory), and the digital twin accurate mapping layout of the physical production line is completed in the digital twin simulation software, so as to realize the intuitive display of the automobile wheel hub intelligent manufacturing production line in a visual form in the digital twin software;

[0077] In the above step 4, if Figure 5 As shown in the figure, the behavior attribute modeling of the digital twin production line includes the mutual drive between the production units of automobile wheel manufacturing, the connection signals between equipment, the action scripts and data statistics modeling;

[0078] In the above step 5, if Figure 5 As shown, the logical attribute modeling of the digital twin production line includes modeling the motion coordinates, motion range, motion relationship, and motion variables of each production unit component or joint in automobile wheel manufacturing;

[0079] In the above step 6, if Figure 5As shown, the data communication modeling of the digital twin production line requires the allocation of IP addresses to each production unit to realize the linkage between models for production process simulation and physical entity mapping; it also includes the modeling of data interaction interfaces between digital models of each production unit (such as action signal interface, grab / place signal interface, in-place signal interface, additional signal interface) and virtual communication interface modeling (such as robot end effector interface, joint drive data interface, trigger action signal interface, equipment status data interface);

[0080] In the above step 7, the digital twin production line drive script editing refers to connecting the various attributes and communication interfaces of the device model through the connection script, driving the twin model movement in a script manner, thereby realizing the construction of the device twin model; through the established device twin model drive scripts and communication interfaces, testing is carried out in the digital twin virtual environment, and real-time data interaction between device twin models is realized through the virtual-real communication interface, thereby driving the operation of the twin model to verify whether the digital twin model conforms to the processing, detection, transmission, and sorting actions and functions of each unit of the physical production line, and finally realizing the construction and verification of the entire digital twin production line system;

[0081] In the above step 8, the joint debugging and simulation optimization of the digital twin system of the automobile wheel hub intelligent production line refers to connecting the unit modules of the production line through the network, and connecting with the digital twin simulation system platform by writing PLC programs to verify the functional implementation of each unit and perform optimization and debugging.

[0082] In one embodiment of the present application, Figure 6 ,Joint debugging and simulation optimization includes the following process steps:

[0083] S8.1, PLC program writing, that is, to realize the control between various production units by writing PLC programs;

[0084] S8.2, define signals, define and match the control signal interfaces between various production units of the automobile wheel hub;

[0085] S8.3, trajectory making, i.e. the industrial robot realizes the picking and placing functions of workpieces or tools in each production unit;

[0086] S8.4, address matching, performing signal address matching on the control signal interface between various production units of the automobile wheel hub;

[0087] S8.5, industrial robot program editing, industrial robot program editing to realize the picking and placing functions of workpieces or tools in each production unit;

[0088] S8.6, PLC program debugging;

[0089] S8.7, Process Validation.

[0090] Example 2: Please refer to Figure 1-Figure 8 The present invention provides a technical solution: a method for constructing a smart manufacturing production line for automobile wheels based on digital twins. The present invention makes corresponding improvements to the technical problems mentioned in the background technology. The system includes a physical production line layer, a data layer, a digital twin production line layer, and an application service layer. By constructing a mapping between the various production elements of the actual production line of automobile wheels, that is, a full-scale perception of the production line’s people, machines, materials, and environment, the physical production line layer includes an execution unit, a processing unit, a storage unit, a transmission unit, and a detection unit. The geometric properties, physical properties, behavioral properties, motion logic, and data communication of multiple modules are fully mapped. The properties of the physical production line for smart manufacturing of automobile wheels are connected to the digital twin production line through a driving script to complete the construction of digital twin models of each production unit. Finally, a high degree of consistency between the twin models of each production equipment and the actual equipment in terms of geometry, physics, behavior, and logic is established.

[0091] The physical production line layer is the data source for the three-dimensional modeling of the digital twin production line and the production and processing information; the physical production line of the intelligent manufacturing of automobile wheel hubs includes a physical equipment module and a data perception module. The physical equipment module includes multiple elements such as execution unit, processing unit, tool unit, sorting unit, grinding unit, detection unit, storage unit, general control unit, and staff; the data perception module includes multiple elements such as various sensors, programmable logic controllers, industrial computers, motion controllers, and network infrastructure. Its function is to collect basic parameters of physical equipment, material information, operating data, and environmental status data, and provide communication links for the host computer software to send commands to various types of equipment, collect data instructions, and interact with data transmission. It supports the control of signal transmission and orderly processing of various devices, and provides an interface with the data layer to provide a data source for the information service layer. The organic combination of the physical equipment module and the perception module realizes the orderly and coordinated operation of various devices in the physical production line layer.

[0092] The data layer guides the collection, transmission, integration, analysis and driving of data. Its role is to achieve interconnection between various parts of the system and ensure stable operation of the system. The twin data of the data layer includes real-time data generated by the physical production line, as well as related data generated by the digital twin model and application service system. The data layer uploads and stores the data collected from the physical entity layer to the server. Part of the data flows into the digital twin production layer as the data source for driving the twin model. The other part of the data is used in the service layer to provide big data statistical analysis support for the application service layer, realizing data visualization, status monitoring and fault diagnosis of the application service layer.

[0093] The data layer uses S7, OPC UA, Modbus TCP, ProfiNet, and DeviceNet multi-source heterogeneous data acquisition methods to collect data, respectively meeting the collection requirements of multiple production data of the execution unit, processing unit, detection unit, and storage unit; the OPC UA server is built through third-party software and data acquisition cards to complete data collection, and the built OPC UA server is connected to the OPC UA client in the digital twin production line to form a data transmission bridge, so that the collected data structure is standardized and data transmission and interaction are realized in the digital twin production line layer and application service layer;

[0094] The digital twin production line layer is based on the accurate mapping of the physical production line layer entities in the virtual space based on 3D modeling technology. It conducts all-round digital modeling of the geometric model, assembly constraint relationship, color material, behavior attribute, logical attribute and data interface of each production factor of the physical production line layer, and builds a digital twin production line that is highly realistic with the physical production line. The digital twin production line layer uses the data collected by the physical production line entity layer and uses logic scripts to drive the twin model in real time, reproduce the physical production line processing action, signal transmission and control multiple attributes in the digital twin production line system, and provide real-time feedback on the dynamic and static characteristics of the physical production line.

[0095] The application service layer includes data visualization, workshop information management system, Internet of Things platform and database; the information service layer is the basis for realizing online simulation, monitoring, evaluation, optimization, prediction and decision-making of the entire process, all elements and the entire flow of the workshop; users interact with the digital twin system through the application service layer to realize three-dimensional visualization monitoring of the production line equipment status and product status in all elements and the entire process, and open up the information flow and data flow of the entire digital twin system; by analyzing, storing and optimizing the data obtained from the physical production line and the digital twin production line, the data is introduced into multiple workshop information management systems such as enterprise resource planning, manufacturing execution system, product data management and warehouse management system, and the data is integrated, analyzed and iteratively optimized in the workshop information management system, and fed back to the digital twin production line system for verification.

[0096] The specific implementation of this embodiment is as follows:

[0097] like Figure 3As shown in the figure, the automobile wheel hub intelligent manufacturing production line system based on digital twin integrates the industrial Internet and digital twin technology, including the physical production line layer, data layer, digital twin production line layer and application service layer; by constructing the mapping between the various production elements of the actual production line, that is, the production line’s people, machines, materials, and environment are all-roundly perceived, including the geometric properties, physical properties, behavioral properties, motion logic and data communication of the execution unit, processing unit, storage unit, transmission unit, and detection unit modules. The properties of the physical production line are connected with the digital twin production line through the driving script to complete the construction of the digital twin model of each device; the equipment twin model finally established is highly consistent with the actual equipment in terms of geometry, physics, behavior, and logic production elements.

[0098] In one embodiment of the present application, the physical production line layer is the foundation and carrier of the entire digital twin production line system. It is responsible for the data source of the three-dimensional model modeling of the digital twin production line and the production and processing information. The intelligent manufacturing of automobile wheels includes a series of process processes such as outbound, processing, detection, transmission, and warehousing. The physical production line includes a physical equipment module and a data perception module. The physical equipment module is the basis of the operation of the workshop, mainly including industrial robots, CNC machining centers, tool units, sorting units, grinding units, detection units, storage units, general control units, and staff elements; the data perception module includes various sensors, programmable logic controllers PLCs, industrial computers, motion controllers, and network infrastructure elements. Its function is to collect basic parameters, material information, operating data, and environmental status data of physical equipment, and provide communication links for the host computer software to send commands to various types of equipment, collect data instructions, and transmit and interact with data. It is the support for controlling the signal transmission and orderly processing of each device, and provides an interface with the data layer to provide a data source for the information service layer. It is a necessary condition for building and driving the operation of the digital twin production line. The organic combination of the physical equipment module and the perception module can realize the orderly and coordinated operation of each device in the physical production line layer.

[0099] In one embodiment of the present application, the data layer is the basis for the effective connection and operation of the various parts of the digital twin production line system. Its function is to connect the various parts of the system, realize the interconnection of the various parts of the system, guide the completion of data collection, transmission, integration, analysis and driving, and ensure the stable operation of the system. The twin data of the data layer includes real-time data generated by the physical production line, as well as related data generated by the digital twin model and application service system. It is the core driver of the operation of the digital twin system.

[0100] The data layer uploads the data collected from the physical entity layer and stores it on the server. Part of the data flows into the digital twin production line layer as the data source for driving the twin model; the other part of the data is used in the service layer to provide big data statistical analysis support for the application service layer, and realize data visualization, status monitoring and fault diagnosis in the application service layer. The intelligent manufacturing production line of automobile hubs involves many devices, multiple data sources and various collection protocols. Therefore, OPC UA technology is used to design S7, OPC UA, Modbus TCP, ProfiNet, and DeviceNet multi-source heterogeneous data collection methods in the data collection layer for data collection, which can respectively realize the collection needs of industrial robots, CNC processing units, inspection units, and storage units. The OPC UA server is built through third-party software and data acquisition cards to complete data collection. The built OPC UA server is connected to the OPC UA client in the digital twin production line to form a data transmission bridge, so that the collected data structure is standardized and data transmission and interaction between the digital twin production line layer and the application service layer are realized.

[0101] The digital twin production line layer is based on the accurate mapping of the physical production line layer entities in the virtual space based on 3D modeling technology. It conducts all-round digital modeling of the geometric model, assembly constraint relationship, color material, behavior attribute, logical attribute and data interface of each production factor of the physical production line layer, and builds a digital twin production line that is highly realistic with the physical production line. The digital twin production line layer uses the data collected by the physical production line entity layer, uses the logic script to drive the twin model in real time, reproduces the processing action, signal transmission and control attributes of the physical production line in the digital twin production line system, and provides real-time feedback on the dynamic and static characteristics of the physical production line. It is an important foundation for building a digital twin 3D visualization monitoring platform.

[0102] In the production design and planning stage, the production process is simulated through the digital twin production line to obtain the production efficiency of the production line under different layout and configuration conditions, and a more reasonable production line planning layout is sought through optimization; during the formal production operation of the production line, the operation of the digital twin production line is driven by the collected real-time production data, so as to realize multi-angle and all-round real-time visual monitoring of the production operation status of the physical production line. In addition, by using a two-way data transmission interaction channel with the physical production line layer, the digital twin production line is combined with the physical production line, the application service layer and the twin data to form a digital twin production line system, which is driven by real-time data, thereby completing the synchronous operation of the physical production line manufacturing process to the digital twin production line.

[0103] The application service layer includes data visualization, workshop information management system (ERP, MES, PDM, WMS), Internet of Things platform, and database. The information service layer is the basis for realizing the application of simulation, monitoring, evaluation, optimization, prediction, and decision-making in the entire process, all elements, and all flows of the workshop. Users interact with the digital twin system through the application service layer to realize three-dimensional visualization monitoring of the production line equipment status and product status in all elements and the entire process, open up the information flow and data flow of the entire digital twin system, and analyze, store and optimize the data obtained from the physical production line and the digital twin production line, and introduce the data into the enterprise resource planning (ERP), manufacturing execution system (MES), product data management (PDM), warehouse management system (WMS) workshop information management system, and perform fusion analysis and iterative optimization of the data in the workshop information management system, and feed it back to the digital twin production line system for verification.

[0104] In order to build a twin model that is highly close to the physical device and can map the physical functions with high precision, the device twin model modeling is divided into model property setting, data communication interface setting and driver script part.

[0105] like Figure 5 As shown, the attribute settings of the twin equipment model of the automobile wheel production line include modeling of geometric attributes, physical attributes, behavioral attributes, and logical attributes. The geometric attributes include the shape, size, positional relationship, and assembly relationship of the equipment, which can be constructed in 3D software (UG, CATIA); the physical attributes include the material, mass, speed, acceleration, and torque parameters of the equipment, and consistency modeling is performed in the 3D model according to the physical properties of the equipment entity; the behavioral attributes include mutual drive between devices, connection signals between devices, action scripts, and data statistics; the logical attributes include the motion coordinates, motion range, motion relationship, and motion variables of equipment components or joints.

[0106] like Figure 5 As shown, in order to realize the linkage between models of production process simulation and physical entity mapping, data communication settings need to allocate IP addresses, establish data interaction interfaces between digital models (such as action signal interface, grabbing and placement signal interface, arrival signal interface and additional connection interface) and virtual-reality data communication interfaces (such as robot end effector interface, joint drive data interface, trigger action signal interface and equipment status data interface).

[0107] The script-driven setting is to connect the various attributes and communication interfaces of the device model through a connection script, and drive the movement of the twin model in a scripted manner, thereby realizing the construction of the device twin model. Through the established device twin model driving scripts and communication interfaces, tests are carried out in the digital twin virtual environment, and real-time data interaction between device twin models is realized through the virtual-reality communication interface, thereby driving the operation of the twin model to verify whether the digital twin model conforms to the processing, detection, transmission, and sorting action behaviors and functions of each unit of the physical production line, and finally realizing the construction and verification of the entire digital twin production line system.

[0108] like Figure 7 As shown, the industrial robot is 3D modeled in the 3D modeling software (CATIA) according to its physical shape, size, positional relationship and assembly relationship, and then rendered, and then the digital twin 3D models of the flange end of the execution unit quick-change module, the translation slide, and the workbench module are constructed in sequence; then, the constructed 3D model of the execution unit is imported into the digital simulation software PQfactory for secondary modeling of physical property modeling, behavioral property modeling, and logical property modeling; finally, the data communication interaction interface of the virtual and real industrial robots is established, and a driver connection script program is written to meet the data interaction and linkage between the twin industrial robots and other unit elements.

[0109] like Figure 8 As shown in the figure, according to the entity shape, size, position relationship and assembly relationship of the CNC machining center, the CNC machine tool is 3D modeled in the 3D modeling software (CATIA), and then rendered, and then the digital twin 3D models of the automatic tool magazine, control system module, and workbench module are constructed in sequence; then, the constructed 3D model of the machining unit is imported into the digital simulation software PQfactory for secondary modeling of physical property modeling, behavioral property modeling, and logical property modeling; finally, the data communication interaction interface of the virtual and real machining units is established, and a driver connection script program is written to meet the data interaction and linkage between the twin machining unit and other unit elements.

[0110] In one embodiment of the present application, each unit of the production line is connected to the digital twin system for debugging and communication to achieve real-time virtual-real linkage; the communication connection method includes wired network and / or wireless network; among them, wired network communication includes: Ethernet and / or RS485; wireless network includes: any one or more combinations of 5G and / or WiFi.

[0111] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0112] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for constructing an automobile wheel hub intelligent manufacturing production line based on digital twins, characterized in that: The following steps are involved: S1, simulates the 2D layout of the physical production line for automobile wheel manufacturing; S2, based on the two-dimensional plane layout of the physical production line of automobile wheel hub manufacturing, combined with the geometric properties and physical properties of the physical production line, construct a three-dimensional model of the physical production line of automobile wheel hub manufacturing; S3, importing the three-dimensional model of the automobile wheel hub manufacturing production line in step S2 into the digital twin simulation software, and completing the digital twin production line layout; S4, behavioral attribute modeling for the digital twin production line; S5, logical attribute modeling for the digital twin production line; S6, data communication modeling for digital twin production lines; S7, edit drive scripts for digital twin production lines; Among them, in the above step S1, the automobile wheel hub manufacturing physical production line includes an execution unit, a tool unit, a processing unit, a detection unit, a sorting unit, a storage unit, a general control unit and a production line environment; the two-dimensional plane layout is: the execution unit is arranged in the center of the factory, the tool unit and the processing unit are arranged on the north side of the execution unit; the sorting unit and the detection unit are arranged on the south side of the execution unit; the storage unit is arranged on the west side of the execution unit; the general control unit is arranged on the east side of the execution unit; the execution unit intelligent control rail realizes the coordination of taking and putting workpieces or tools of each production unit; Wherein, in the above step S2, the three-dimensional modeling of each production unit of the physical production line of automobile wheel hub manufacturing includes execution unit modeling, tool unit modeling, processing unit modeling, detection unit modeling, sorting unit modeling, storage unit modeling, general control unit modeling, production line environment modeling and personnel modeling; the geometric attributes include the shape, size, position relationship and assembly relationship of the equipment; the physical attributes include the specific material, quality, rigidity, strength, speed and acceleration of each equipment unit component, and the geometric attribute and physical attribute information of each equipment unit are imported into the three-dimensional software for construction, wherein the three-dimensional software adopts UG or CATIA, and is saved as an STL format file; Among them, in the above step S3, the three-dimensional model files constructed in step 2 are sequentially imported into the digital twin simulation software, the digital twin simulation software adopts PQfactory, and the digital twin accurate mapping layout of the physical production line is completed in the digital twin simulation software, so as to realize the intuitive display of the automobile wheel hub intelligent manufacturing production line in a visual form in the digital twin software; Wherein, in the above step S4, the behavior attribute modeling includes modeling of the mutual drive between various production units of automobile wheel hub manufacturing, the connection signals between equipment, the action scripts and the data statistics; Wherein, in the above step S5, the logic attribute modeling includes modeling the motion coordinates, motion range, motion relationship, and motion variables of each production unit component or joint of the automobile wheel hub manufacturing; In the above step S6, the data communication modeling is to allocate IP addresses to each production unit to achieve linkage between models for production process simulation and physical entity mapping; data interaction interface modeling and virtual communication interface modeling between digital models of each production unit; Among them, in the above step S7, the script editing refers to connecting the various attributes and communication interfaces of the equipment model through a connection script, driving the movement of the twin model in a script manner, thereby realizing the construction of the equipment twin model; through the established twin model driving scripts and communication interfaces of each production equipment, testing is carried out in the digital twin virtual environment, and real-time data interaction between equipment twin models is realized through the virtual-reality communication interface, thereby driving the operation of the twin model to verify whether the digital twin model conforms to the processing, detection, transmission, and sorting actions and functions of each unit of the physical production line, and finally realizing the construction and verification of the entire digital twin production line system.

2. The method for constructing an automobile wheel hub intelligent manufacturing production line based on digital twin according to claim 1, characterized in that: It also includes joint debugging of the intelligent production line of automobile wheels and the digital twin system, and simulation optimization; connecting the various production unit modules through the network, and docking with the digital twin simulation system platform by writing PLC programs to verify the functional realization of each production unit and perform optimization debugging; The joint debugging and simulation optimization includes the following process steps: S8-1,PLC programming; S8-2, define signal; S8-3, trajectory making; S8-4, address matching; S8-5, industrial robot program editing; S8-6,PLC program debugging; S8-7, process verification.

3. The automobile wheel hub intelligent manufacturing production line system based on digital twin is characterized by: The system includes a physical production line layer, a data layer, a digital twin production line layer and an application service layer. By constructing a mapping between the various production elements of the actual production line of automobile wheels, that is, a full-scale perception of the production line's people, machines, materials and environment is performed. The physical production line layer includes the execution unit, processing unit, storage unit, transmission unit and detection unit. The geometric properties, physical properties, behavioral properties, motion logic and data communication of multiple modules are fully mapped. The properties of the physical production line of automobile wheel intelligent manufacturing are connected with the digital twin production line through a driving script to complete the construction of the digital twin model of each production unit. Finally, a high degree of consistency between the twin model of each production equipment and the actual equipment in terms of geometric, physical, behavioral and logical production elements is established.

4. The automotive wheel hub intelligent manufacturing production line system based on digital twin according to claim 3 is characterized in that: The physical production line layer is the data source for modeling the three-dimensional model of the digital twin production line and production and processing information; the physical production line of intelligent manufacturing of automobile wheel hubs includes a physical equipment module and a data perception module. The physical equipment module includes an execution unit, a processing unit, a tool unit, a sorting unit, a grinding unit, a detection unit, a storage unit, a general control unit, and multiple staff elements; the data perception module includes multiple elements such as various sensors, programmable logic controllers, industrial computers, motion controllers, and network infrastructure. Its function is to collect basic parameters, material information, operating data, and environmental status data of physical equipment, and provide a communication link for the host computer software to send commands to various types of equipment, collect data instructions, and interact with data transmission. It is the support for controlling the signal transmission and orderly processing of each device, and provides an interface with the data layer to provide a data source for the information service layer. The organic combination of the physical equipment module and the perception module realizes the orderly and coordinated operation of each device in the physical production line layer.

5. The automobile wheel hub intelligent manufacturing production line system based on digital twin according to claim 4 is characterized in that: The data layer guides the completion of data collection, transmission, integration, analysis and driving. Its function is to realize the interconnection of various parts of the system and ensure the stable operation of the system. The twin data of the data layer includes real-time data generated by the physical production line, as well as related data generated by the digital twin model and application service system. The data layer uploads and stores the data collected from the physical entity layer on the server, and part of the data flows into the digital twin production line layer as the data source for driving the twin model. The other part of the data is used for the service layer to provide big data statistical analysis support for the application service layer, so as to realize data visualization, status monitoring and fault diagnosis of the application service layer.

6. The automobile wheel hub intelligent manufacturing production line system based on digital twin according to claim 5 is characterized in that: The data layer adopts S7, OPC UA, Modbus TCP, ProfiNet, and DeviceNet multi-source heterogeneous data acquisition methods to collect data, respectively realizing the collection requirements of multiple production data of the execution unit, processing unit, detection unit, and storage unit; an OPC UA server is built through third-party software and data acquisition cards to complete data collection, and the built OPC UA server is connected to the OPC UA client in the digital twin production line to form a data transmission bridge, so that the collected data structure is unified and standardized, and data transmission and interaction are realized in the digital twin production line layer and application service layer.

7. The automotive wheel hub intelligent manufacturing production line system based on digital twin according to claim 6 is characterized in that: The digital twin production line layer is based on the three-dimensional modeling technology to accurately map the entities of the physical production line layer in the virtual space, and conducts comprehensive digital modeling of the geometric models, assembly constraints, color materials, behavioral attributes, logical attributes and data interfaces of each production factor of the physical production line layer to build a digital twin production line that is highly realistic with the physical production line; the digital twin production line layer uses the data collected by the physical production line entity layer and uses logic scripts to drive the twin model in real time, reproduce the physical production line processing actions, signal transmission and control multiple attributes in the digital twin production line system, and provide real-time feedback on the dynamic and static characteristics of the physical production line.

8. The automobile wheel hub intelligent manufacturing production line system based on digital twin according to claim 7 is characterized in that: The application service layer includes data visualization, workshop information management system, Internet of Things platform and database; the information service layer is the basis for realizing online simulation, monitoring, evaluation, optimization, prediction and decision-making of the whole process, all elements and the whole flow of the workshop; users interact with the digital twin system through the application service layer to realize three-dimensional visualization monitoring of the full elements and the whole flow of the production line equipment status and product status, and open up the information flow and data flow of the entire digital twin system; By analyzing, storing and optimizing the data obtained from the physical production lines and digital twin production lines, the data is introduced into multiple workshop information management systems such as enterprise resource planning, manufacturing execution system, product data management, and warehouse management system. The data is integrated, analyzed and iteratively optimized in the workshop information management system, and fed back to the digital twin production line system for verification.

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