Digital twin simulation system and simulation method based on automobile production continuous line
By collecting production line motor control signals and vehicle position sensing signals, combined with virtual queue algorithm, the problem of information delay and inaccurate vehicle initialization position in the digital twin system is solved, and the accurate correlation and synchronous display of vehicles and vehicles are realized .
Patent Information
- Application Number
- CN202411653689.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-19
- Publication Date
- 2025-02-14
AI Technical Summary
The existing digital twin system delays information when relying on sensing data, lacks skateboard position information and vehicle binding information, resulting in inaccurate vehicle initialization position, resulting in queue delay and misalignment.
By adding the acquisition of production line motor control signals, obtaining motor code block values and adding vehicle position sensing signals, combined with updating the virtual queue algorithm, the vehicle position and vehicle association relationship are accurately calculated to achieve real-time synchronization.
The problem of information delay and inaccurate vehicle initialization position in the digital twin system is solved, and the accurate correlation between vehicles and vehicles is achieved, ensuring that the digital twin scene is synchronized with on-site vehicle movement.
Smart Images
Figure CN119439933A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of automobile assembly line production, and in particular to a digital twin simulation system and a simulation method based on an automobile production line. Background Art
[0002] At present, the common continuous line simulation method for automotive digital twins is to drive through the vehicle fleet provided by the enterprise's MES system. The vehicles are composed of a long queue of continuous skateboards. The main friction drive device installed after the first position slowly pushes the skateboard into the continuous queue, so that the entire continuous line moves forward slowly. Because personnel will stand on the skateboard to work, there must be no gap in the middle of the continuous line. Therefore, if no continuous skateboard is pushed into the continuous line, the continuous line will trigger a stop alarm until a new skateboard can be pushed into the continuous line.
[0003] The digital twin generates a slide and a vehicle according to the queue, and moves forward at a constant speed at the set speed, simulating the real environment where the vehicle leaves the post or enters the next process under the push of the online slide. When the vehicle and slide at the last post trigger the sensor outside the continuous line, it means that the vehicle has left the continuous line station, the vehicle queue in the production equipment control system changes, and the station vehicle goes offline. The Internet of Things system collects the changes in the vehicle queue on the real production line at a fixed frequency and pushes the changed data to the digital twin system.
[0004] In the digital twin system, the vehicle is first initialized at the center of each position, the moving speed of the continuous line in the driving logic is set, the vehicle starts to move forward at a constant speed, the digital twin system receives the data change, and passes the data to the driving logic. Because the vehicle signal at the last position disappears, the vehicle and skateboard in the digital twin move to the sensor mark, the deleted model disappears and goes offline. And so on, all vehicles in the previous position are pushed to the next position.
[0005] The existing technology mainly has the following defects: 1. When the digital twin system relies only on in-place sensor data, the overall information is delayed.
[0006] 2. The digital twin system does not have the skateboard location information and the skateboard-vehicle binding information. During initialization, because there is no vehicle information, it is impossible to initialize the vehicle at the correct position using only the queue, resulting in the mismatch between the number of vehicles and the workstations, and there are problems such as insufficient vehicles and misplacement.
[0007] 3. Because the initialization position is incorrect, the queue displayed in the digital twin is delayed compared to the on-site one. Some intermediate workstations that rely on sensors also have empty queue data due to information delays, resulting in fewer vehicles and misalignment in the overall queue.
[0008] 4. Because there is a certain delay between the display effect in the digital twin and the on-site effect, it cannot correspond to the offline signal of the sensor data. There may be automated workstation signals behind it, which cannot be matched. In other words, the vehicle in the digital twin cannot reach the correct position at the right time. Summary of the invention
[0009] The purpose of the present invention is to provide a digital twin simulation system and simulation method based on a continuous automobile production line, which solves the problems existing in the above-mentioned prior art by adding methods such as collecting production line motor control signals, obtaining motor code block values, and adding vehicle in-place sensor signals, combined with updating the virtual queue algorithm.
[0010] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is to provide a digital twin simulation system based on a continuous automobile production line, forming a virtual production line that is a twin of the real production line that applies the continuous line process, and is used for remote real-time management of vehicle production on the production line, characterized in that it includes a production control system, an Internet of Things system and a digital twin system; The production control system is connected to the production line, drives the carrier carrying the vehicle along the production line through one or more positions, and controls the production equipment installed at the position to complete the production process corresponding to the position for the vehicle; the production control system also sends sensor information to the Internet of Things system; the Internet of Things system integrates the sensor information to generate production line status information and sends it to the digital twin system; the production line status information includes production line operation information and carrier position information; The digital twin system combines the production line operation information and the vehicle positioning information to obtain the association relationship between the vehicle and the vehicle, and simultaneously calculates the virtual queue information based on the production line operation information, and further updates and displays the virtual production line status based on the virtual queue information, thereby realizing the twin effect of the virtual production line.
[0011] Further, the production control system comprises a control module and a sensor module; The control module is connected to the production line and the production equipment, and sends control information to the production line and the production equipment to control the actions of the production line and the production equipment. At the same time, the sensor information is generated based on the control information and sent to the Internet of Things system; the sensor module is connected to the production line, collects sensor signals, converts them into the sensor information, and sends them to the Internet of Things system.
[0012] Furthermore, the sensing module is connected to a carrier sensor; the carrier sensor is disposed at an entrance of the production line to identify whether the carrier is located at the entrance of the production line; and the sensing module generates carrier positioning information as the sensing information.
[0013] Furthermore, the control module is connected to the lift motor, the main friction motor and the brake friction motor on the production line, and controls the actions of the lift motor, the main friction motor and the brake friction motor according to production needs, thereby driving the vehicle to enter the production line or driving the vehicle to move along the production line; The elevator motor is used to drive the vehicle to enter the production line; when the elevator motor is activated, a new vehicle on-line signal is generated as the sensor information; the main friction motor and the brake friction motor cooperate with each other to drive the vehicle forward along the production line; the main friction motor is used to accelerate the movement of the production line, and the brake friction motor is used to decelerate the movement of the production line; when the main friction motor or the brake friction motor is activated, a motor drive signal is generated as the sensor information.
[0014] Furthermore, the control module is also connected to the motor sensor; the motor sensor is a code block sensor installed on the main friction motor and the brake friction motor; the code block sensor is arranged on the main friction motor and the brake friction motor, and reads the code block value information representing the accumulated rotation angle as the sensing information.
[0015] Furthermore, the Internet of Things system includes a data acquisition module, a data storage module, a data calculation module and a data communication module; The data acquisition module uses the data communication module to obtain the sensor information from the production control system and delivers it to the data calculation module; the data calculation module uses the data storage module to integrate the sensor information, generate the production line status information, and finally transmits the production line status information to the digital twin system through the data communication module.
[0016] Furthermore, the digital twin system includes a data preprocessing module, a data calculation module, a queue data module, a drive logic module and an animation module; The data preprocessing module performs format conversion on the received production line status information and sends it to the data calculation module; the data calculation module generates production line event information based on the production line status information and sends it to the queue data module; The queue data module records the changes of the vehicles on and off the line, and uses the production line event information to bind the vehicles and the carriers, and update the virtual queue information; when the changes of the virtual queue information require updating the animation, the drive logic module is notified and the virtual queue information is sent to the drive logic module; The driving logic module maintains the virtual production line status. When receiving the virtual queue information, it updates the virtual production line status based on the virtual queue information and sends it to the animation module. The animation module updates the animation according to the virtual production line status, generates a visualized virtual production line and displays it.
[0017] The present invention also discloses a simulation method using the above-mentioned digital twin simulation system based on the automobile production line, which is characterized by comprising the steps of: Step S10, initializing the production control system, the Internet of Things system and the digital twin system; in the queue data module in the digital twin system, establishing a virtual queue and initializing all cells in the virtual queue to be empty; the cells are used to store vehicle information and vehicle location information, and correspond one to one with the vehicles; Step S20, the production control system controls the vehicle to enter the production line; Step S30, the production control system collects and reports the sensor information to the Internet of Things system; Step S40, the IoT system converts the information into production line status information and sends it to the digital twin system; Step S50, the digital twin system associates the vehicle and the carrier based on the production line status information; Step S60, the queue data module calculates new virtual queue information based on the production line status information; Step S70, when the virtual queue information changes, the digital twin system updates the virtual production line status; Step S80, the digital twin system updates the animation according to the state of the virtual production line and displays the virtual production line; Step S90, the vehicle completes the production process at the current position, and the production control system controls the vehicle to enter the next position; if there is no new vehicle entering the production line at present, jump to step S30; otherwise jump to step S20.
[0018] Furthermore, in step S50, the step of associating the vehicle and the carrier includes the following sub-steps: Step S51, reading the production line operation information and the carrier positioning information in the production line status information; When the carrier in position information indicates that the carrier is located at the entrance of the production line, the production line operation information is used to read whether the elevator motor is in operation, thereby determining whether a new vehicle is on the line.
[0019] If it is a new car online, go to step S52, otherwise jump to step S53; Step S52, obtaining the vehicle information from the production line operation information, filling it into the first unit of the virtual queue, and proceeding to step S54; Step S53, clearing the vehicle information in the first unit of the virtual queue; Step S54, completing the association between the vehicle and the vehicle, and updating the vehicle position information of a unit in the virtual queue.
[0020] Furthermore, the step of calculating the new virtual queue information in step S60 includes the following sub-steps: Step S61, reading the production line operation information in the production line status information, and obtaining the cumulative displacement value of the production line from the production line operation information; Step S62, updating the vehicle position information in each unit in the virtual queue according to the accumulated displacement value; Step S63, comparing the carrier position information in the unit at the end of the virtual queue with the preset line end position information, if the carrier position information is greater than the line end position information, proceed to step S64, otherwise jump to step S67; Step S64, clearing the unit at the end of the virtual queue, thereby removing the vehicle from the virtual production line, and releasing the vehicle associated with the unit; Step S65, moving the vehicle position information and the vehicle information in each unit in the virtual queue to the next unit; Step S66, clearing the vehicle position information and the vehicle information in the first unit in the virtual queue; Step S67, completing the virtual queue update.
[0021] In view of the above technical features, the present invention is based on a digital twin simulation system and simulation method for a continuous automobile production line to solve the problems of the continuous line vehicle queue being later than the actual situation on site and the relationship between vehicles and vehicles. Compared with the prior art, the present invention has the following advantages: 1. The present invention can combine the length data of the production line and the station calibration point data to accurately calculate the specific position of each carrier, ensuring that the digital simulation is synchronized with the actual situation of the vehicle movement on site. The carrier in the digital twin scene can reach the predetermined position at the right time within a very small error range and synchronize with other automated equipment to complete the corresponding process flow. In addition, the parameter value can be appropriately increased to allow the carrier to reach the target position slightly earlier.
[0022] 2. The present invention solves the problem of the association between carriers and vehicles. In addition to mastering the location information of the carrier, it can also understand the relevant information of the products (i.e., vehicles) carried on the carrier, and incorporate it into the queue data for management and maintenance. After obtaining the information of the carrier and the vehicle, the vehicle and the carrier are initialized together in a binding relationship, and their accuracy is consistent with the scene. After the queue reaches a stable state, the acquired queue data remains accurate and consistent at any time. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Figure 1 It is a system block diagram of a preferred embodiment of the digital twin simulation system based on the automobile production line of the present invention; Figure 2 It is a production line schematic diagram of a production control system in a preferred embodiment of the digital twin simulation system based on a continuous automobile production line of the present invention; Figure 3 It is a method flow chart of a preferred embodiment of the simulation method of the digital twin simulation system based on the automobile production line of the present invention.
[0024] In the figure: 100-production control system, 200-Internet of Things system, 300-digital twin system; 110-control module, 120-sensor module; 111-elevator motor, 112-main friction motor, 113-brake friction motor, 114-code block sensor; 121-carrier sensor; 201-data acquisition module, 202-data calculation module, 203-data storage module, 204-data communication module; 301 - data preprocessing module, 302 - data calculation module, 303 - queue data module, 304 - driving logic module, 305 - animation module. DETAILED DESCRIPTION
[0025] The present invention will be further described below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms fall within the scope limited by the appended claims of the application equally.
[0026] See also Figure 1 and Figure 2The present invention discloses a digital twin simulation system based on a continuous automobile production line. It corresponds to a real production line that applies a continuous line process, and forms a twin virtual production line according to the state of the real production line. In this way, the production line manager can remotely obtain the status of the real production line in real time and remotely manage the production of vehicles on the real production line. A preferred embodiment of the system is composed of a production control system 100, an Internet of Things system 200 and a digital twin system 300.
[0027] On the actual production line that applies the continuous line process, there are multiple positions, and production equipment is installed at each position. Once the production line is started, it will not stop. The vehicle is placed on the production line and continues to move forward with the production line. The vehicle to be processed enters from the entrance of the production line, is loaded onto the vehicle, and passes through each position in turn driven by the vehicle. When the vehicle arrives at the position, the vehicle does not stop. The workers at the position use production equipment or automated production equipment to follow the vehicle to process the vehicle and complete the production process corresponding to the current position. A vehicle passes through all the positions on the production line while moving continuously, that is, it completes all the production processes corresponding to this production line, and finally leaves the production line.
[0028] The production control system 100 is connected to the real production line, and it includes a control module 110 and a sensor module 120. The control module 110 is used to control the production line and the production equipment. It is connected to the production line and the production equipment and sends control information to the production line and the production equipment according to the production plan. After receiving the control information, the production line will drive the vehicle to move between positions, including going online, moving through positions, and going offline. After receiving the control information, the production equipment that supports automated production will process the vehicle at the current position to complete the production process. At the same time, the control module 110 will also generate sensor information based on the sent control information, which will be collected by the Internet of Things system 200.
[0029] Specifically, the control module 110 is connected to different motors installed on the production line, such as the lift motor 111, the main friction motor 112 and the brake friction motor 113. The lift motor 111 is located at the entrance of the production line and is used to transfer the vehicle to the carrier to complete the on-line action. The main friction motor 112 and the brake friction motor 113 are used to drive the conveyor belt on the production line. The main friction motor 112 frictionally contacts the conveyor belt, drives the conveyor belt to accelerate or keep moving forward, thereby pushing the carrier to pass through each position one by one along the production line in the forward direction. The brake friction motor 113 also frictionally contacts the conveyor belt, but it drives the conveyor belt to run in the reverse direction to slow down the operation of the conveyor belt. While sending a command to make the lift motor 111 work, the control module 110 records the details of the motor drive signal, and generates sensor information based on it and transmits it to the Internet of Things system 120. Corresponding to the lift action, the control module 110 generates a signal for identifying the new car on the line as sensor information. Corresponding to the actions of the main friction motor 112 and the brake friction motor 113, the control module 110 generates a signal for identifying the operation of the transmission line as sensing information. In this embodiment, a code block sensor 114 is also installed on the main friction motor 112 and the brake friction motor 113. There are two code block sensors 114, which are installed on the main friction motor 112 and the brake friction motor 113 respectively. They act as motor sensors to read the code block value information representing the cumulative rotation angle as sensing information. With the main friction motor 112 and the brake friction motor 113 equipped with the code block sensor 114, the digital twin system 300 can determine the position of the carrier and the vehicle on the production line by obtaining the precise position of the conveyor belt of the production line from the code block value information. In other embodiments, such as in the scenario of upgrading an old production line, when the production line is not suitable for installing the code block sensor 114, the digital twin system 300 obtains the operating status of the main friction motor 112 and the brake friction motor 113 through the motor drive signal, such as the operating time and the operating speed, and then calculates and estimates the precise position of the conveyor belt, thereby relatively accurately estimating the position of the carrier and the vehicle on the production line.
[0030] The sensor module 120 itself does not control the production line or production equipment, and cannot manipulate their actions. The sensor module 120 is connected to various sensors installed on the production line, collects sensor signals, and converts sensor information, which is collected by the Internet of Things system 200. In this embodiment, the sensor module 120 is connected to the carrier sensor 121 installed at the entrance of the production line. The function of the carrier sensor 121 is to identify whether a carrier has arrived at the entrance of the production line, and is generally implemented as a photoelectric sensor. The carrier in place signal reported by the carrier sensor 121 to the sensor module 120 is an analog signal, which is converted by the sensor module 120 into digital carrier in place information and becomes sensor information that can be recognized by the Internet of Things system 200.
[0031] The production control system 100 contains a large number of control signals for controlling the production of the real production line and sensor signals reflecting various states of the real production line, but the digital twin system 300 does not actually need all of the sensor signals. At the same time, the equipment in the production control system 100 will also be updated as the production line is updated, and the format of the sensor signals reported by it will also change accordingly. Therefore, the Internet of Things system 200 is introduced and placed between the production control system 100 and the digital twin system 300. The Internet of Things system 200 only extracts the sensor signals required by the digital twin system 300 from the production control system 100, and sends them to the digital twin system 300 after regularizing their formats. In this way, when there are equipment changes in the production control system 100, the Internet of Things system 200 can be used to isolate the differences, maintain the stability of the digital twin system 300, and improve the reliability of the digital twin system 300. The Internet of Things system 200 includes a data acquisition module 201, a data calculation module 202, a data storage module 203, and a data communication module 204. The data communication module 204 is a unified interface for the Internet of Things module 200 to exchange information with the outside world. It is used for data communication with the production control system 100 and for data communication with the digital twin system 300. The data acquisition module 201 is the entrance of the Internet of Things system 200. It uses the data communication module 204 to read the sensor information from the production control system 100 and deliver it to the data calculation module 202. The data calculation module 202 is used to complete the data format conversion. The data calculation module 202 uses the data storage module 203 to complete the data conversion work: the sensor information is saved in the data storage module 203, and then the sensor information is formatted in the data storage module 203 to generate the production line status information. After completing the data conversion, the data calculation module 202 still uses the data communication module 204 to transmit the production line status information to the digital twin system 300. The production line status information includes the production line operation information and the carrier position information. Specifically, the production line operation information includes the new vehicle on-line information from the elevator motor 111, the operation status information and code block value information (if any) from the main friction motor 112 and the brake friction motor 113. The sensing information from the carrier sensor 121 includes the carrier in-position information.
[0032] The digital twin system 300 reads the product status information sent from the Internet of Things system 200, and then generates an animation showing the status of the virtual production line based on the product status information, and displays it to the production line manager. The virtual production line can be displayed remotely, so that managers can obtain the status of the real production line remotely, especially in the scenario of multiple production lines, so that production can be managed more effectively. The digital twin system 300 includes a data preprocessing module 301, a data calculation module 302, a queue data module 303, a drive logic module 304 and an animation module 305.
[0033] The data preprocessing module 301 receives the production line status information, performs necessary format conversion according to the requirements of the internal modules of the digital twin system 300, and then sends the corrected production line status information to the data calculation module 302. The data calculation module 302 reads the production line operation information and the carrier positioning information from the production line status information, generates the production line event information, and sends it to the queue data module 303.
[0034] Specifically, when the carrier is in place (obtained from the carrier in place information), and there is an action of the elevator motor 111, and the conveyor belt is running (obtained in combination with the running status of the main friction motor 112 and the brake friction motor 113), it is determined that a new car has entered the production line, and the production line event information of the new car entering the line is generated. At the same time, updating the code block value will also generate new production line event information.
[0035] A virtual queue will be established in the queue data module 303. Each unit in the virtual queue corresponds to each vehicle on the virtual production line and contains the location information of the vehicle. When vehicle information is filled in the unit, it means that the vehicle and the vehicle are associated in the virtual queue, and the vehicle in the corresponding real production line is loaded on the vehicle. On the contrary, when the cell is empty, it means that the corresponding vehicle on the virtual production line is not associated with the vehicle. The queue data module 303 is driven by the production line event information from the data calculation module 302. When new production line event information is received, the queue data module 303 updates the unit information in the virtual queue to complete the changes in vehicle association and vehicle movement. After processing the production line event information, the queue data module 303 will determine whether the update of the current virtual queue information needs to trigger animation changes, and only send the virtual queue information to the drive logic module 304 when the animation needs to be updated, thereby notifying the drive logic module 304.
[0036] The virtual production line is different from the real production line. In the real production line, the actual motor controls the operation of the production line. In the virtual production line, the virtual production line status is maintained by the drive logic module 304. The drive logic module 304 sets the drive logic according to the virtual queue information, including various flags of the virtual production line, so as to change the virtual production line status. For example, if it is found that all vehicles in the virtual queue have entered the next position, the flag blocking the operation of the virtual production line is cancelled, so that the animation module 305 starts to display the picture of the vehicle moving forward on the virtual production line. When the vehicle position 1 displayed on the animation module 305 is consistent with that in the virtual queue, the flag blocking the operation of the virtual production line is reset, so that the vehicle in the animation stops at the current position, which is consistent with the real production line, forming a twin effect. After the drive logic module 304 updates the drive logic, the animation module 305 generates a new animation to reflect the latest virtual production line status, and then displays it visually to the production line management personnel.
[0037] See also Figure 3The present invention also discloses a simulation method using the above-mentioned digital twin simulation system based on the automobile production line, a preferred embodiment of which comprises the steps of: Step S100, initializing each system.
[0038] Before production begins, the production control system, IoT system, and digital twin system are initialized. In particular, the queue data module in the digital twin system establishes a virtual queue during the initialization phase. After initialization, the virtual queue contains the same number of cells as the number of vehicles on the real production line, and all cells are set to empty, which means that no vehicle is loaded on each vehicle on the current virtual production line. In addition to saving vehicle information for the corresponding vehicle associated with the current vehicle (i.e., the vehicle loaded by the current vehicle), the unit also saves the location information of the vehicle in the production line.
[0039] Step S200: The vehicle enters the production line.
[0040] After the production line starts running, the vehicle follows the conveyor belt on the production line to the production line entrance and is identified by the vehicle sensor installed near the production line entrance. Then, the production control system controls the elevator motor to operate according to production needs, and the new vehicle is driven by the elevator and lowered onto the vehicle, thus completing the loading and entering the production line along the conveyor line with the vehicle.
[0041] Step S300: the production control system reports sensor information.
[0042] The production control system generates sensor information based on the control information sent by the control module, such as the new vehicle on-line signal reflecting the action of the elevator motor, the transmission line operation signal and the code block value signal reflecting the action of the main friction motor and the brake friction motor. At the same time, the production control system uses the sensor module to collect the signal of the vehicle sensor and generate the vehicle in-position information as the sensor information. All sensor information is transmitted and reported to the Internet of Things system.
[0043] Step S400: The Internet of Things system reports production line status information.
[0044] After receiving the sensor information, the IoT system converts it into production line status information that can be recognized by the digital twin system and sends it to the digital twin system.
[0045] Step S500: The digital twin system attempts to associate the vehicle and the carrier.
[0046] Step S501, determine whether a new car is online.
[0047] The data calculation module uses the production line operation information and the carrier placement information in the production line status information to determine whether there is a new vehicle on the line. When the carrier placement information reaches the data calculation module, it means that there is currently an empty carrier arriving at the production line entrance. The data calculation module reads the information from the production line operation information to see whether the elevator motor is in motion. If the elevator motor is in motion, then there is a new vehicle on the line, and the process goes to step S502 to start associating the carrier and the vehicle. Otherwise, it means that there is currently no new vehicle on the line, and an empty carrier will enter the production line. At this time, the process jumps to step S503 to skip the association.
[0048] Step S502, fill in vehicle information.
[0049] The data calculation module obtains the corresponding vehicle information from the production line operation information, that is, the information of the vehicle from the elevator drive device to the carrier on the real production line, and fills it into the first unit of the virtual queue, thereby also associating the vehicle and the carrier in the virtual production line. After completion, enter step S504.
[0050] Step S503, clear vehicle information.
[0051] The data calculation module clears the vehicle information in the first unit of the virtual queue, that is, sets the vehicles in the virtual queue to be empty.
[0052] Step S504: the carrier and the vehicle are associated, and the carrier position information of the first unit is updated to the production line entrance.
[0053] Step S600: The digital twin system updates the virtual queue information.
[0054] The queue data module calculates new virtual queue information based on the production line status information.
[0055] Step S601, obtaining the cumulative displacement value of the production line.
[0056] The queue data module extracts the production line operation information from the production line status information, and obtains the cumulative displacement value of the production line.
[0057] Depending on the production line, the cumulative displacement value can be obtained in different ways. If the production line operation information contains code block value information, the queue data module can directly obtain the cumulative displacement value of the conveyor belt on the production line from the code block value. The queue data module only needs to handle the overflow of the code block value: if it overflows upward, the subsequent code block value needs to add the product of the number of overflows and the maximum value of the code block value. If it overflows downward, it is generally an abnormal situation and an alarm can be processed. If the production line operation information does not contain code block values, the queue data module reads information related to the main friction motor and the brake friction motor, such as motor running time, motor running speed, etc., to calculate the cumulative displacement value of the conveyor belt on the production line. As long as the sliding friction accounts for a small proportion of the power transmission process between the main friction motor, the brake friction motor and the conveyor belt, this method can also be used to relatively accurately calculate the cumulative displacement value.
[0058] In practice, because the transmission line operates in a loop, the queue data module only needs to know the exact position of a certain point on the transmission line after multiple cycles, and does not need to actually record the cumulative displacement value of the production line since its operation. The queue data module can only record the result of the cumulative displacement value modulo the length of the production line. For example, if the modulo result is 0, it means that the current production line conveyor belt position is consistent with the initialization time. Similarly, if the modulo result is half of the production line length, it means that the current production line conveyor belt has run forward half the length of the production line, and the conveyor belt that was initially displaced in the second half of the production line is currently circulating to the first half of the production line.
[0059] Step S602, updating the vehicle position.
[0060] The carriers are continuously running on the production line following the conveyor belt, and their positions relative to the conveyor belt are fixed. Therefore, after obtaining the position of the conveyor belt on the production line based on the cumulative displacement value, the current position of each carrier on the production line can be inferred. After obtaining the new cumulative displacement value, the queue data module further updates the carrier position information in each unit in the virtual queue, which is equivalent to moving each carrier backward a distance in the virtual queue, which is calculated by the cumulative displacement value.
[0061] Step S603, determining whether any vehicle is offline.
[0062] In continuous production, vehicles follow the carriers and move forward continuously, while the carriers are fixed on the transmission line and move forward in sequence. Therefore, only when the carrier at the end of the production line completely leaves the current position can it be considered that the carrier has left the current position. If there is a vehicle on the carrier, the vehicle will also follow the carrier off the line.
[0063] Therefore, when the carrier position is updated, the queue data module reads the carrier position information in the unit at the end of the virtual queue and compares it with the preset line end position information. If the carrier position information is greater than the line end position information, go to step S604, otherwise jump to step S607.
[0064] Step S604: the vehicle goes offline and the vehicle association is terminated.
[0065] The queue data module clears the vehicle position information in the unit at the end of the queue, thereby removing the vehicle from the virtual production line. If the vehicle is associated with a vehicle, the queue data module also clears the vehicle information in the unit at the end of the queue, thereby removing the association.
[0066] Step S605: update all units in the virtual queue.
[0067] The queue data module moves the vehicle position information and vehicle information in each unit in the virtual queue to the next unit, thereby indicating that all vehicles in the virtual production line move down one position.
[0068] Step S606, empty the first unit.
[0069] The queue data module clears the carrier position information and vehicle information in the first unit of the virtual queue, thereby indicating that the first position in the virtual production line is idle.
[0070] Step S607, completing the virtual queue update.
[0071] The virtual queue is only visible inside the queue data module. In the digital twin system, other modules generate virtual queue information based on the virtual queue through the queue data module and learn the details of the current virtual queue. When the information in the unit in the virtual queue changes, the queue data module generates new virtual queue information.
[0072] Step S700, updating the virtual production line status.
[0073] When the virtual queue information changes, the drive logic module in the digital twin system will be activated. The drive logic module will update the drive logic used to control the virtual production line according to the new virtual queue information, thereby adjusting the state of the virtual production line.
[0074] Step S800: update and display the virtual production line animation.
[0075] The animation module in the digital twin system recognizes the change in the virtual production line status, generates a new animation based on the new virtual production line status, and then displays it to the production line manager. At this point, the status of the real production line is displayed to the production line manager by the virtual production line twin.
[0076] Step S900: the vehicle completes the production process.
[0077] After the vehicle completes all production processes at the current position, the production control system controls the vehicle to enter the next position. If there is no new vehicle that needs to enter the production line, jump to step S300, otherwise jump to step S200.
[0078] It is particularly pointed out that, in addition to the tight continuous line mentioned in the above embodiment, whenever a transport vehicle is used to carry products and moves forward at a constant speed on a defined track, each transport vehicle follows the previous one. The power source can be the transport vehicle's own power system, or it can be powered by a linear system. Such linear systems can be regarded as a form of continuous line, and the movement of the entire transport team should maintain consistency and synchronization. The slings or grips of the chassis line in automobile manufacturing and the floor plate chain conveyor belts of the final line are all forms of continuous lines.
[0079] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.
Claims
1. A digital twin simulation system based on a continuous automobile production line, forming a virtual production line that is a twin of the real production line using continuous production line technology, and used for remote real-time management of vehicle production on the production line, characterized in that: Includes production control systems, IoT systems and digital twin systems; The production control system is connected to the production line, drives the carrier carrying the vehicle along the production line through one or more positions, and controls the production equipment installed at the position to complete the production process corresponding to the position for the vehicle; the production control system also sends sensor information to the Internet of Things system; The IoT system integrates the sensor information to generate production line status information, and sends it to the digital twin system; the production line status information includes production line operation information and carrier positioning information; The digital twin system combines the production line operation information and the vehicle positioning information to obtain the association relationship between the vehicle and the vehicle, and simultaneously calculates the virtual queue information based on the production line operation information, and further updates and displays the virtual production line status based on the virtual queue information, thereby realizing the twin effect of the virtual production line.
2. The digital twin simulation system based on the automobile production line according to claim 1 is characterized in that: The production control system comprises a control module and a sensor module; The control module is connected to the production line and the production equipment, sends control information to the production line and the production equipment, thereby controlling the actions of the production line and the production equipment, and generates the sensor information based on the control information and sends it to the Internet of Things system; The sensor module is connected to the production line, collects sensor signals, converts them into the sensor information, and sends them to the Internet of Things system.
3. The digital twin simulation system based on the automobile production line according to claim 2 is characterized in that: The sensing module is connected to a carrier sensor; the carrier sensor is disposed at an entrance of the production line to identify whether the carrier is located at the entrance of the production line; the sensing module generates carrier in-position information as the sensing information.
4. The digital twin simulation system based on the automobile production line according to claim 2 is characterized in that: The control module is connected to the lift motor, the main friction motor and the brake friction motor on the production line, and controls the actions of the lift motor, the main friction motor and the brake friction motor according to production needs, so as to drive the vehicle to enter the production line or drive the vehicle to move along the production line; The elevator motor is used to drive the vehicle to enter the production line; when the elevator motor is in motion, a new vehicle on-line signal is generated as the sensor information; The main friction motor and the brake friction motor cooperate with each other to drive the vehicle to move forward along the production line; the main friction motor is used to accelerate the movement of the production line, and the brake friction motor is used to decelerate the movement of the production line; When the main friction motor or the brake friction motor is operated, a motor driving signal is generated as the sensing information.
5. The digital twin simulation system based on the automobile production line according to claim 4 is characterized in that: The control module is also connected to the motor sensor; the motor sensor is a code block sensor installed on the main friction motor and the brake friction motor; the code block sensor is arranged on the main friction motor and the brake friction motor, and reads the code block value information representing the accumulated rotation angle as the sensing information.
6. The digital twin simulation system based on the automobile production line according to claim 1 is characterized in that: The Internet of Things system includes a data acquisition module, a data storage module, a data calculation module and a data communication module; The data acquisition module uses the data communication module to obtain the sensor information from the production control system and delivers it to the data calculation module; the data calculation module uses the data storage module to integrate the sensor information, generate the production line status information, and finally transmits the production line status information to the digital twin system through the data communication module.
7. The digital twin simulation system based on the automobile production line according to claim 1 is characterized in that: The digital twin system includes a data preprocessing module, a data calculation module, a queue data module, a drive logic module and an animation module; The data preprocessing module performs format conversion on the received production line status information and sends it to the data calculation module; the data calculation module generates production line event information based on the production line status information and sends it to the queue data module; The queue data module records the changes of the vehicles on and off the line, and uses the production line event information to bind the vehicles and the carriers, and update the virtual queue information; when the changes of the virtual queue information require updating the animation, the drive logic module is notified and the virtual queue information is sent to the drive logic module; The driving logic module maintains the virtual production line status. When receiving the virtual queue information, it updates the virtual production line status based on the virtual queue information and sends it to the animation module. The animation module updates the animation according to the virtual production line status, generates a visualized virtual production line and displays it.
8. A simulation method using the digital twin simulation system based on the automobile production line as claimed in claim 1, characterized in that: Contains steps: Step S10, initializing the production control system, the Internet of Things system and the digital twin system; in the queue data module in the digital twin system, establishing a virtual queue and initializing all cells in the virtual queue to be empty; the cells are used to store vehicle information and vehicle location information, and correspond one to one with the vehicles; Step S20, the production control system controls the vehicle to enter the production line; Step S30, the production control system collects and reports the sensor information to the Internet of Things system; Step S40, the IoT system converts the information into production line status information and sends it to the digital twin system; Step S50, the digital twin system associates the vehicle and the carrier based on the production line status information; Step S60, the queue data module calculates new virtual queue information based on the production line status information; Step S70, when the virtual queue information changes, the digital twin system updates the virtual production line status; Step S80, the digital twin system updates the animation according to the virtual production line status and displays the virtual production line; Step S90, the vehicle completes the production process at the current position, and the production control system controls the vehicle to enter the next position; if no new vehicle enters the production line, jump to step S30; Otherwise, jump to step S20.
9. The simulation method based on the digital twin simulation system of the automobile production line according to claim 8 is characterized in that: In step S50, the step of associating the vehicle and the carrier includes the following sub-steps: Step S51, reading the production line operation information and the carrier positioning information in the production line status information; When the carrier in-position information indicates that the carrier is located at the entrance of the production line, the operation information of the production line is read to determine whether the elevator motor is in motion, thereby determining whether a new vehicle is on the line; If it is a new car online, go to step S52, otherwise jump to step S53; Step S52, obtaining the vehicle information from the production line operation information, filling it into the first unit of the virtual queue, and proceeding to step S54; Step S53, clearing the vehicle information in the first unit of the virtual queue; Step S54, completing the association between the vehicle and the vehicle, and updating the vehicle position information of a unit in the virtual queue.
10. The simulation method based on the digital twin simulation system of the automobile production line according to claim 8 is characterized in that: The step of calculating the new virtual queue information in step S60 comprises the following sub-steps: Step S61, reading the production line operation information in the production line status information, and obtaining the cumulative displacement value of the production line from the production line operation information; Step S62, updating the vehicle position information in each unit in the virtual queue according to the accumulated displacement value; Step S63, comparing the carrier position information in the unit at the end of the virtual queue with the preset line end position information, if the carrier position information is greater than the line end position information, proceed to step S64, otherwise jump to step S67; Step S64, clearing the unit at the end of the virtual queue, thereby removing the vehicle from the virtual production line, and releasing the vehicle associated with the unit; Step S65, moving the vehicle position information and the vehicle information in each unit in the virtual queue to the next unit; Step S66, clearing the vehicle position information and the vehicle information in the first unit in the virtual queue; Step S67, completing the virtual queue update.