Digital twinning system applied to pelletizing factory and manufacturing method of digital twinning system

Abstract

A digital twinning system applied to a pelletizing factory and a manufacturing method thereof belong to the technical field of digital twinning systems and comprise a three-dimensional comprehensive display module, a process flow animation module, a process virtual simulation module, a roaming inspection module, a production monitoring module, a video module, a personnel positioning module and a business data visualization module. And all the devices are connected with the pellet digital twinning system master control center. A manufacturing method for a three-dimensional model of a digital twin system comprises the steps that BIM software is used for opening the BIM model, the model used in the design stage is subjected to lightweight processing, the model subjected to lightweight processing is exported as an fbx file in the BIM software, Unity 3D software is used for importing the fbx file, materials, chartlets and illumination means are added in the Unity 3D software, then rendering is conducted, and the three-dimensional model is optimized. And finally, a three-dimensional model which can be used in the digital twin system is formed. The three-dimensional model has high precision and authenticity, and the technological process can be clearly restored.

Description

Technical Field

[0001] The present invention belongs to the technical field of digital twin systems, and in particular relates to a digital twin system applied to a pelletizing plant. Background Art

[0002] Factory digital twins rely on the development of 3D modeling technology, Internet of Things (IoT) technology, data processing technology, and large-screen visualization technology. With the development of the above technologies in recent years and the improvement of the digitalization and intelligence level of pelletizing plants, the application of digital twin systems of pelletizing plants has become more and more extensive.

[0003] BIM design is usually used in the factory design stage to improve design and construction efficiency. The BIM model is not better utilized in the production and operation stage of the pelletizing plant. When the digital twin project is implemented, the three-dimensional modeling is re-performed, and the model accuracy and authenticity are low. The common digital twin system realizes the reproduction of the three-dimensional scene and the integration of a small part of the data. The data information contained is not sufficient to support the production decision-making of the pelletizing plant. Summary of the invention

[0004] In order to solve the above-mentioned problems, the present invention proposes: a digital twin system applied to a pelletizing plant, comprising a three-dimensional comprehensive display module, a process flow animation module, a process virtual simulation module, a roaming inspection module, a production monitoring module, a video module, a personnel positioning module, and a business data visualization module. The three-dimensional comprehensive display module, the process flow animation module, the process virtual simulation module, the roaming inspection module, the production monitoring module, the video module, the personnel positioning module, and the business data visualization module are all connected to the general control center of the pelletizing digital twin system.

[0005] Furthermore, the three-dimensional comprehensive display module constructs a step-by-step visualization of the pelletizing plant area, workshop, production line, and equipment through three-dimensional modeling;

[0006] The three-dimensional comprehensive display module includes factory-level model display, workshop-level model display, and equipment-level model display;

[0007] The plant-level model display conducts 1:1 detailed modeling of the entire pelletizing plant buildings and process workshops, and the main structure of the buildings. The facades of the buildings and workshops are displayed through a transparent effect, and their internal models can be presented. Other process sections are indicated by white films. Through plant-level modeling, the entire factory workshop layout, workshop appearance model, and production process flow are truly restored, and the spatial locations of various workshops are displayed, clearly and completely restoring the entire factory environment;

[0008] The workshop-level model display performs three-dimensional modeling of the structure, environment, and equipment in the workshop, truly restores the spatial position of various equipment in the production equipment model, clearly and completely displays the entire workshop environment, and ensures that the equipment type can be clearly identified by the naked eye;

[0009] The equipment-level model display performs three-dimensional modeling of the equipment appearance, internal components and its auxiliary equipment, and produces a three-dimensional exploded view of key equipment: the various components of the equipment are separated and moved in the order of equipment disassembly in the form of a three-dimensional animation view, so that equipment maintenance personnel can intuitively and clearly understand the internal composition and working principle of the equipment.

[0010] Furthermore, the process flow animation module is based on a three-dimensional scene, animating the actual process flow of the pelletizing and the equipment status, and performing a three-dimensional animation display according to the on-site operation status, showing the key equipment actions and material flow;

[0011] The process animation module includes: chain grate trolley, rotary kiln rotation, flame in rotary kiln, ring cooler rotation, pelletizing disk rotation, belt conveyor and material flow;

[0012] The chain grate trolley, the chain grate movement and the rotation animation of the transmission equipment at both ends, the material on the chain grate moves with the trolley, and the movement speed is associated with the chain grate speed data;

[0013] The rotary kiln rotates, the rotary kiln body rotates, and the rotation speed is associated with the rotary kiln speed data;

[0014] The flame in the rotary kiln dynamically displays flame animation, and the flame size is associated with the coal injection amount data;

[0015] The ring cooler rotates, the ring cooler trolley rotates, the material on the trolley rotates with the trolley, and the rotation speed is related to the speed of the ring cooler;

[0016] The ball-making disk rotates, and a rotation animation of the ball-making disk is dynamically displayed, and the rotation speed is associated with the speed data of the ball-making disk;

[0017] The belt conveyor and material flow dynamically display the movement animation of each belt conveyor and the material on the belt conveyor, and its movement speed is associated with the belt conveyor speed data.

[0018] Furthermore, the process virtual simulation module performs production line start-up and shutdown simulation, heat transfer process simulation, and finished product prediction on the pellet production line based on the three-dimensional scene;

[0019] The production line start-stop simulation displays the pelletizing production line, equipment sequential start-up, sequential stop, emergency stop and other production processes in the form of 3D animation and display of operating parameters in an offline state;

[0020] The heat transfer process simulation establishes a three-dimensional heat transfer mathematical model based on various temperature monitoring data, and describes the temperature distribution of flue gas and pellets in the production process in the form of a three-dimensional temperature field;

[0021] The finished product prediction is based on the production parameters of each process link of the pelletizing process and uses multivariate model prediction technology to predict the composition, output, particle size and other technical indicators of the finished product ore.

[0022] Furthermore, the roaming inspection module simulates roaming in the three-dimensional model from a first-person perspective, including manual roaming and automatic roaming. During the roaming and inspection process, the equipment operation status and related production parameters are checked, and the camera is called to observe the actual situation on site;

[0023] The manual roaming is performed by operating the left and right mouse buttons or by selecting a preset roaming point in the three-dimensional scene;

[0024] The automatic roaming, after setting the roaming speed in the system and selecting the automatic roaming option, automatically roams according to the preset roaming points from a first-person perspective.

[0025] Furthermore, the production monitoring module displays the real-time monitoring values ​​of sensors in the process flow based on the three-dimensional scene, displays the statistical information of a certain process link in the form of an information panel, and displays the historical information of the monitoring values ​​in the form of a chart.

[0026] Furthermore, the video module: displays the number and specific location of video surveillance in a three-dimensional scene, and selects and plays the video data of the corresponding camera, displays it in the form of a small window, and plays the video surveillance screen in real time; provides a video linkage function, when starting the production line, the video automatically follows the equipment startup sequence; when the equipment fails, the video information associated with the device is automatically opened.

[0027] Furthermore, the personnel positioning module integrates and displays the information of personnel position and personnel trajectory in the three-dimensional scene, realizes personnel, real-time position positioning, motion trajectory tracking and tracing; links with the intelligent camera terminal, and actively tracks the special personnel and trajectories entering the venue;

[0028] Furthermore, the business data visualization module displays the production management data, equipment management data, and safety and environmental management data of the pelletizing plant through large-screen visualization technology;

[0029] The production management data performs statistical analysis on the production data, and displays the production plan, production performance, production line comparison, inventory information, energy consumption information, and output information through a reasonable large-screen layout and a variety of charts;

[0030] The equipment management data performs statistical analysis on the equipment information, and displays the maintenance plan, maintenance results, equipment operation analysis, equipment failure analysis, and equipment life analysis through reasonable large screens and diversified charts;

[0031] The safety and environmental management data conducts statistical analysis on safety and environmental information, and displays safety hazard information, hazard source information, and environmental data analysis through reasonable large screens and diverse charts.

[0032] A method for making a three-dimensional model of a digital twin system fully utilizes a BIM model in a design phase and satisfies the problem that the digital twin system model needs to be lightweight. The BIM model is opened using BIM software, and the model used in the design phase is lightweighted by means of face number control, removal of redundant details, structural reconstruction, volume compression, and removal of material texture. The lightweight model is exported as an fbx file in the BIM software, and the fbx file is imported using Unity3D software. The three-dimensional model is optimized by rendering in Unity3D software after adding materials, mapping, and lighting, and finally a three-dimensional model that can be used in the digital twin system is formed.

[0033] The beneficial effects of the present invention are as follows: the three-dimensional model of the present invention has high accuracy and authenticity, can clearly restore the process flow, intuitively display the structure of key equipment, and timely discover production anomalies through the linkage of data and models; it integrates multi-business data visualization to improve decision-making capabilities. A method for making a three-dimensional model of a digital twin system, making full use of the BIM model in the design stage, while meeting the problem that the digital twin system model needs to be lightweight, using BIM software to open the BIM model, and lightweighting the model used in the design stage by means of face number control, removal of redundant details, structural reconstruction, volume compression, and removal of material textures, exporting the lightweight model as an fbx file in the BIM software, importing the fbx file using Unity3D software, and optimizing the three-dimensional model by rendering in Unity3D software after adding materials, mapping, and lighting, and finally forming a three-dimensional model that can be used in the digital twin system. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a functional framework diagram of a digital twin system of a pelletizing plant of the present invention;

[0035] Figure 2 This is a functional schematic diagram of the business data visualization module of the present invention;

[0036] Figure 3 This is a flow chart of a method for making a three-dimensional model of a digital twin system of the present invention. DETAILED DESCRIPTION

[0037] In order to make the technical means and objectives of the present invention easy to understand, the present invention is further described below in combination with specific implementation methods. A digital twin system applied to a pelletizing plant, such as Figure 1 As shown, it includes a three-dimensional comprehensive display module, a process flow animation module, a process virtual simulation module, a roaming inspection module, a production monitoring module, a video module, a personnel positioning module, and a business data visualization module. The three-dimensional comprehensive display module, the process flow animation module, the process virtual simulation module, the roaming inspection module, the production monitoring module, the video module, the personnel positioning module, and the business data visualization module are all connected to the general control center of the pelletizing digital twin system.

[0038] The three-dimensional comprehensive display module constructs a step-by-step visualization of the pelletizing plant area, workshops, production lines, and equipment through three-dimensional modeling.

[0039] Furthermore, the three-dimensional comprehensive display module in the present invention includes a factory-level model display, a workshop-level model display, and an equipment-level model display.

[0040] The plant-level model display is to carry out 1:1 detailed modeling of the entire pelletizing plant area buildings and process workshops, modeling of the main structure of the buildings, and display the facades of the buildings and workshops through a transparent effect, which can show their internal models, and other process sections are indicated by white films. Through plant-level modeling, the entire factory workshop layout, workshop appearance model, production process flow, etc. are truly restored, and the spatial location of various workshops is displayed, clearly and completely restoring the entire factory environment.

[0041] The workshop-level model display performs three-dimensional modeling of the structure, environment, and equipment within the workshop, truly restores the production equipment model to show the spatial positions of various equipment, clearly and completely displays the entire workshop environment, and ensures that the equipment type can be clearly identified by the naked eye.

[0042] The equipment-level model display performs three-dimensional modeling of the equipment appearance, internal components and its auxiliary equipment, and produces a three-dimensional exploded view of key equipment: the various components of the equipment are separated and moved in the order of equipment disassembly in the form of a three-dimensional animation view, so that equipment maintenance personnel can intuitively and clearly understand the internal composition and working principle of the equipment.

[0043] The process flow animation module: based on the three-dimensional scene, animates the actual process flow of the pelletizing and the equipment status, and displays the three-dimensional animation according to the on-site operating status, showing the key equipment movements, material flow, etc.

[0044] Further, the process flow animation module described in the present invention includes but is not limited to: chain grate machine trolley, rotary kiln rotation, flame in rotary kiln, ring cooler rotation, pelletizing disk rotation, belt conveyor and material flow.

[0045] The chain grate machine trolley, the chain grate machine movement and the rotation animation of the transmission equipment at both ends, the material on the chain grate machine moves with the trolley, and the movement speed is associated with the chain grate machine speed data.

[0046] The rotary kiln rotates, the rotary kiln body rotates, and the rotation speed is associated with the rotary kiln speed data.

[0047] The flame in the rotary kiln dynamically displays flame animation, and the flame size is associated with the coal injection amount data.

[0048] The ring cooler rotates, the ring cooler trolley rotates dynamically, the material on the trolley rotates along with the trolley, and the rotation speed is related to the speed of the ring cooler.

[0049] The ball-making disk rotates, and a rotation animation of the ball-making disk is dynamically displayed, and the rotation speed is associated with the speed data of the ball-making disk.

[0050] The belt conveyor and material flow dynamically display the movement animation of each belt conveyor and the material on the belt conveyor, and its movement speed is associated with the belt conveyor speed data.

[0051] The process virtual simulation module: based on the three-dimensional scene, performs production line start and stop simulation, heat transfer process simulation, finished product prediction, etc. on the pellet production line.

[0052] The production line start and stop simulation displays the pelletizing production line, equipment sequential start, sequential stop, emergency stop and other production processes in the form of three-dimensional animation and display of operating parameters in an offline state.

[0053] The heat transfer process simulation establishes a three-dimensional heat transfer mathematical model based on various temperature monitoring data, and describes the temperature distribution of flue gas and pellets in the production process in the form of a three-dimensional temperature field.

[0054] The finished product prediction is based on the production parameters of each process link of the pelletizing process and uses multivariate model prediction technology to predict the composition, output, particle size and other technical indicators of the finished product ore.

[0055] The roaming inspection module: The system can simulate the first-person perspective to roam in the three-dimensional model, including manual roaming and automatic roaming. During the roaming and inspection process, the equipment operation status and related production parameters can be viewed, and the camera can be called up to observe the actual situation on site.

[0056] The manual roaming can be performed by operating the left and right buttons of the mouse or by selecting a preset roaming point to roam in the three-dimensional scene.

[0057] The automatic roaming can set the roaming speed in the system. After selecting the automatic roaming option, the system automatically roams according to the preset roaming points from a first-person perspective.

[0058] The production monitoring module: based on the three-dimensional scene, displays the real-time monitoring values ​​of sensors in the process flow, displays the statistical information of a certain process link in the form of an information panel, and displays the historical information of the monitoring values ​​in the form of a chart.

[0059] The video module: can display the number and specific location of video surveillance in a three-dimensional scene, and can select and play the video data of the corresponding camera, display it in the form of a small window, and play the video surveillance screen in real time. Provide video linkage function, when starting the production line, the video can automatically follow according to the equipment startup sequence; when the equipment fails, the video information associated with the equipment is automatically opened.

[0060] The personnel positioning module integrates and displays information such as personnel location and personnel trajectory in a three-dimensional scene to realize personnel, real-time location positioning, motion trajectory tracking and tracing; and links with the intelligent camera terminal to actively track special personnel and trajectories entering the site.

[0061] like Figure 2 As shown, the business data visualization module displays the production management data, equipment management data, and safety and environmental management data of the pelletizing plant through large-screen visualization technology.

[0062] The production management data performs statistical analysis on the production data and displays the production plan, production performance, production line comparison, inventory information, energy consumption information, output information, etc. through a reasonable large-screen layout and a variety of charts.

[0063] The equipment management data performs statistical analysis on the equipment information and displays maintenance plans, maintenance results, equipment operation analysis, equipment failure analysis, equipment life analysis, etc. through reasonable large screens and diversified charts.

[0064] The safety and environmental management data conducts statistical analysis on safety and environmental information, and displays safety hazard information, hazard source information, environmental data analysis, etc. through reasonable large screens and diversified charts.

[0065] The present invention also provides a method for making a three-dimensional model of a digital twin system, which fully utilizes the BIM model in the design stage and at the same time meets the need for lightweighting of the digital twin system model.

[0066] The method for making a three-dimensional model of a digital twin system is as follows: Figure 3As shown, use BIM software to open the BIM model, and lightweight the model used in the design phase by means of surface number control, removal of redundant details, structural reconstruction, volume compression, and removal of material textures. Export the lightweight model as an fbx file in the BIM software, and use Unity3D software to import the fbx file. In Unity3D software, optimize the three-dimensional model by adding materials, mapping, lighting, etc. and then rendering it, ultimately forming a three-dimensional model that can be used in the digital twin system.

[0067] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solutions and concepts of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A digital twin system applied to a pelletizing plant, characterized in that: It includes three-dimensional comprehensive display module, process flow animation module, process virtual simulation module, roaming inspection module, production monitoring module, video module, personnel positioning module, and business data visualization module. The three-dimensional comprehensive display module, process flow animation module, process virtual simulation module, roaming inspection module, production monitoring module, video module, personnel positioning module, and business data visualization module are all connected to the general control center of the pelletizing digital twin system.

2. The digital twin system applied to a pelletizing plant according to claim 1, characterized in that: The three-dimensional comprehensive display module constructs a step-by-step visualization of the pelletizing plant area, workshop, production line, and equipment through three-dimensional modeling; The three-dimensional comprehensive display module includes factory-level model display, workshop-level model display, and equipment-level model display; The plant-level model display conducts 1:1 detailed modeling of the entire pelletizing plant buildings and process workshops, and the main structure of the buildings. The facades of the buildings and workshops are displayed through a transparent effect, and their internal models can be presented. Other process sections are indicated by white films. Through plant-level modeling, the entire factory workshop layout, workshop appearance model, and production process flow are truly restored, and the spatial locations of various workshops are displayed, clearly and completely restoring the entire factory environment; The workshop-level model display performs three-dimensional modeling of the structure, environment, and equipment in the workshop, truly restores the spatial position of various equipment in the production equipment model, clearly and completely displays the entire workshop environment, and ensures that the equipment type can be clearly identified by the naked eye; The equipment-level model display performs three-dimensional modeling of the equipment appearance, internal components and its auxiliary equipment, and produces a three-dimensional exploded view of key equipment: the various components of the equipment are separated and moved in the order of equipment disassembly in the form of a three-dimensional animation view, so that equipment maintenance personnel can intuitively and clearly understand the internal composition and working principle of the equipment.

3. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The process animation module is based on a three-dimensional scene, and animates the actual process flow of pelletizing and the equipment status. It performs a three-dimensional animation display according to the on-site operation status, showing the key equipment movements and material flow. The process animation module includes: chain grate trolley, rotary kiln rotation, flame in rotary kiln, ring cooler rotation, pelletizing disk rotation, belt conveyor and material flow; The chain grate trolley, the chain grate movement and the rotation animation of the transmission equipment at both ends, the material on the chain grate moves with the trolley, and the movement speed is associated with the chain grate speed data; The rotary kiln rotates, the rotary kiln body rotates, and the rotation speed is associated with the rotary kiln speed data; The flame in the rotary kiln dynamically displays flame animation, and the flame size is associated with the coal injection amount data; The ring cooler rotates, the ring cooler trolley rotates, the material on the trolley rotates with the trolley, and the rotation speed is related to the speed of the ring cooler; The ball-making disk rotates, and a rotation animation of the ball-making disk is dynamically displayed, and the rotation speed is associated with the speed data of the ball-making disk; The belt conveyor and material flow dynamically display the movement animation of each belt conveyor and the material on the belt conveyor, and its movement speed is associated with the belt conveyor speed data.

4. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The process virtual simulation module performs production line start-up and shutdown simulation, heat transfer process simulation, and finished product prediction on the pellet production line based on a three-dimensional scene; The production line start-stop simulation displays the pelletizing production line, equipment sequential start-up, sequential stop, emergency stop and other production processes in the form of 3D animation and display of operating parameters in an offline state; The heat transfer process simulation establishes a three-dimensional heat transfer mathematical model based on various temperature monitoring data, and describes the temperature distribution of flue gas and pellets in the production process in the form of a three-dimensional temperature field; The finished product prediction is based on the production parameters of each process link of the pelletizing process and uses multivariate model prediction technology to predict the composition, output, particle size and other technical indicators of the finished product ore.

5. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The roaming inspection module simulates the first-person perspective to roam in the three-dimensional model, which includes manual roaming and automatic roaming. During the roaming and inspection process, the equipment operation status and related production parameters are checked, and the camera is called to observe the actual situation on site; The manual roaming is performed by operating the left and right mouse buttons or by selecting a preset roaming point in the three-dimensional scene; The automatic roaming, after setting the roaming speed in the system and selecting the automatic roaming option, automatically roams according to the preset roaming points from a first-person perspective.

6. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The production monitoring module displays the real-time monitoring values ​​of sensors in the process flow based on a three-dimensional scene, displays the statistical information of a certain process link in the form of an information panel, and displays the historical information of the monitoring values ​​in the form of a chart.

7. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The video module: displays the number and specific location of video surveillance in a three-dimensional scene, and selects and plays the video data of the corresponding camera, displays it in the form of a small window, and plays the video surveillance screen in real time; provides a video linkage function, when starting the production line, the video automatically follows the equipment startup sequence; when the equipment fails, the video information associated with the equipment is automatically opened.

8. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The personnel positioning module integrates and displays the information of personnel position and personnel trajectory in the three-dimensional scene, realizes personnel, real-time position positioning, motion trajectory tracking and tracing; and links with the intelligent camera terminal to actively track the special personnel and trajectories entering the site.

9. The digital twin system applied to a pelletizing plant according to claim 2, characterized in that: The business data visualization module displays the production management data, equipment management data, and safety and environmental management data of the pelletizing plant through large-screen visualization technology; The production management data performs statistical analysis on the production data, and displays the production plan, production performance, production line comparison, inventory information, energy consumption information, and output information through a reasonable large-screen layout and a variety of charts; The equipment management data performs statistical analysis on the equipment information, and displays the maintenance plan, maintenance results, equipment operation analysis, equipment failure analysis, and equipment life analysis through reasonable large screens and diversified charts; The safety and environmental management data conducts statistical analysis on safety and environmental information, and displays safety hazard information, hazard source information, and environmental data analysis through reasonable large screens and diverse charts.

10. A method for making a three-dimensional model of a digital twin system, characterized in that: Make full use of the BIM model in the design phase, while meeting the need for lightweight models in the digital twin system. Use BIM software to open the BIM model, and lightweight the model used in the design phase by controlling the number of faces, removing redundant details, reconstructing the structure, compressing the volume, and removing material textures. Export the lightweight model as an fbx file in the BIM software, import the fbx file using Unity3D software, and optimize the three-dimensional model by adding materials, mapping, and lighting in Unity3D software before rendering, ultimately forming a three-dimensional model that can be used in the digital twin system.

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