Unity 3D-based electrolytic driving digital twin system and construction method thereof

Abstract

The invention discloses an electrolytic travelling crane digital twinning system based on Unity 3D and a building method thereof, and belongs to the technical field of electrolytic travelling crane digital twinning. Comprising the steps that an electrolysis driving digital twinborn model containing an electrolysis driving visual geometric model and an electrolysis driving interactive logic model, virtual equipment based on a TIA Portal end and a visual man-machine interaction panel based on Unity 3D are built, and the virtual equipment based on the TIA Portal end is in communication connection with the electrolysis driving digital twinborn model and the visual man-machine interaction panel; a Unity3D-based visual man-machine interaction panel comprises a UI visual interface and an interaction panel, an interaction button is responsible for controlling equipment movement, and the UI visual interface displays the real-time movement condition of an electrolytic travelling crane and various equipment operation parameters in the electrolytic travelling crane; in addition, more intuitive and more reliable work guidance and decision support can be provided for an electrolytic travelling crane operator, so that the electrolytic travelling crane operator can master the running condition of the electrolytic travelling crane more accurately, and problems can be found and solved in time.

Description

Technical Field

[0001] The present invention relates to a digital twin system of an electrolytic crane based on Unity3D and a construction method thereof, and belongs to the technical field of digital twins of electrolytic cranes. Background Art

[0002] Electrolytic copper is an important metal refining method in modern industry and is widely used in electronics, electrical engineering, construction and other fields. The electrolytic crane used in the electrolytic copper process mainly consists of three important parts: mechanical system, actuator and electrical system. The mechanical system includes the bridge composed of the main beam and the end beam, the rails on which the bridge runs, and the trolley frame installed on the bridge. Most of the bridges are box-type structures, and the main beam and the end beam are connected with high-strength bolts to form the main frame of the electrolytic crane. The actuators are mainly large vehicles, small vehicles, hoists, grippers and cabs, etc. Their main function is to use transmission mechanisms such as motors, reducers, wire ropes and drums to drive the electrolytic crane to move in all directions in the workspace. The electrical system includes power supply lines, electrical equipment, monitoring systems and control systems, etc. Its function is to transmit electrical energy to the actuator of the electrolytic crane through cables to complete control instructions.

[0003] In the electrolytic copper production process, the positive and negative plates are extracted from the electrolytic cell by the gripper on the electrolytic crane, and moved and positioned on the production line by the cooperation of the trolley mechanism and the trolley mechanism. During the production process, the plate lifting work is completed by manually operating the bridge crane, and the driver needs to communicate with the ground commander to complete the accurate docking between the plate and the target electrolytic cell, which takes up a lot of human resources. In addition, during the material transportation process, the electrolyte liquid will drip, which may cause pollution to the working environment and increase the safety risks of the operators.

[0004] The essence of digital twins is to integrate multidisciplinary, multi-domain, multi-scale, and multi-dimensional modeling of the physical world in the virtual world, thereby achieving true restoration of the physical world and realizing a technical means of virtual-real interaction between the physical world and the virtual world. Digital twin technology uses digital methods to establish a high-fidelity digital twin model, effectively utilizes and highly integrates multi-source heterogeneous data in physical space and information space, and can perceive, analyze, simulate, predict, and optimize the real-time state and behavior characteristics of actual physical objects. In the manufacturing industry, digital twin technology has become an important means to improve the efficiency of product design, production, and maintenance. With the continuous maturity and popularization of digital technology, the development prospects of digital twin technology are very broad.

[0005] At present, it has become a common practice to use Unity3D to complete digital twin development. As a powerful three-dimensional game engine, Unity3D has powerful real-time 3D rendering technology, which is essential for building realistic digital twin models. In addition, Unity3D provides rich functions and easy-to-use development tools, which can handle complex graphics and physical effects, making digital twin models more realistic and vivid. However, Unity3D is designed for high-quality games and virtual reality applications, and its performance and resource consumption are relatively high. Complete reliance on Unity3D may be subject to performance limitations, functional limitations, increased project complexity and maintenance costs, and a steeper learning curve. Summary of the invention

[0006] The purpose of the present invention is to provide a digital twin system of electrolytic crane based on Unity3D and a construction method thereof, by building a digital twin model of electrolytic crane and a TIA Portal end virtual device, the digital twin model of electrolytic crane is connected to the virtual device for communication based on digital twin, the operation signal is obtained, and the digital twin model of electrolytic crane is driven by the operation data to realize real-time linkage with the virtual device; the digital twin system of electrolytic crane is constructed by combining PLC control with digital twin technology, the PLC ladder diagram design is completed based on Siemens S7-1500 programmable logic controller and TIA Portal fully integrated automation software, and the data interaction between field equipment and monitoring center monitoring station is realized by using industrial Ethernet. And a new UI operation panel is established to replace the traditional operation mode.

[0007] The technical solution adopted by the present invention is: a digital twin system of electrolysis driving based on Unity3D, including

[0008] The digital twin model of the electrolytic crane includes a visualized geometric model of the electrolytic crane and an interactive logical model of the electrolytic crane. The visualized geometric model of the electrolytic crane uses graphics knowledge and mechanics knowledge to achieve digital mapping of the geometric properties of the electrolytic crane equipment to achieve visualization of the equipment object. The interactive logical model of the electrolytic crane describes the production logic and electrolysis process of the electrolytic crane during the electrolysis process. By encapsulating and calling the logical model, the electrolytic crane can reproduce the behavior logic of the electrolysis process.

[0009] The virtual device based on TIA Portal communicates with the electrolysis crane digital twin model and the visual human-machine interaction panel respectively;

[0010] The visual human-machine interaction panel includes a UI visual interface and an interactive panel. The UI visual interface drives the virtual scene under the Unity3D virtual engine through the operation data, and the operating parameters of various equipment in the electrolysis crane are mapped in real time in the visual interactive panel through the Xcharts plug-in and UI Text components in Unity3D. The interactive panel interactively controls the operating mechanism of the electrolysis crane based on the Button option of the UGUI component in Unity3D.

[0011] A method for building a digital twin system of an electrolytic vehicle based on Unity3D, comprising the following steps:

[0012] 1) Build a digital twin model of the electrolytic vehicle that includes a visualized geometric model and an interactive logic model;

[0013] 2) Build a virtual device based on TIA Portal;

[0014] 3) Based on the digital twin technology, the digital twin model of the electrolysis crane is connected to the virtual device to obtain the operation data, and the digital twin model of the electrolysis crane and the virtual device are driven to work in real time through the operation data;

[0015] 4) Build a visual human-computer interaction panel based on the Unity3D platform, including two parts: the UI visualization interface and the interaction panel, and at the same time connect the virtual device with the visual human-computer interaction panel for communication.

[0016] Specifically, the process of building a virtual device based on the TIA Portal includes: establishing the PLC hardware module configuration S7-1500 series PLC, the CPU model is 1515-2PN, three input expansion switch modules DI 32*24VDC HF, and one output expansion switch module DQ 32*24VDC / 0.5; setting the IP address and subnet mask of the PLC through PLCSIM Advanced, and the IP address and subnet mask are consistent with the CPU of the PLC host equipment to establish PUT / GET communication with the TIA Portal to complete the construction of the virtual device on the TIA Portal.

[0017] Specifically, the construction process of the electrolytic driving visualization geometric model is as follows:

[0018] Step 1.1: By analyzing the physical structure of the electrolytic crane, collect the shape, size, spatial position, assembly relationship, material, and color of the on-site electrolytic crane;

[0019] Step 1.2: Use SolidWorks 3D modeling software to build the geometric model of the electrolytic crane: geometric modeling of the trolley, trolley, hanger, gripper, cab, crane main beam, trolley drive, electrolytic cell, trolley frame, liquid receiving tray, trolley drive and accessory parts;

[0020] Step 1.3: Export the STEP file of the electrolytic vehicle geometry model, import the STEP file into 3dsMax, use the Polygon Cruncher lightweight plug-in in 3dsMax to trim the number of vertices and faces in the electrolytic vehicle geometry model, complete the lightweight processing of the electrolytic vehicle geometry model and export the FBX file;

[0021] step1.4: Import the FBX file into the Unity3D engine, restore the electrolysis scene, use VisualStudio to develop a simulation data-driven script, realize the detailed characterization of the electrolysis vehicle's geometric information, and complete the construction of the electrolysis vehicle's visual geometric model.

[0022] Specifically, the construction process of the interactive logic model of electrolytic driving is as follows:

[0023] Step 2.1: Clarify the processing tasks of the electrolytic crane equipment;

[0024] Step 2.2: Use the nested "parent-child nodes" method to organize and divide the internal structure and visual geometric model of the electrolytic vehicle. That is, when the "parent object" moves, the "child object" can only follow the "parent object" for local movement; when the "child object" moves, the movement of the "child object" will not affect the movement of the "parent object".

[0025] Step 2.3: PLC modeling is performed according to the production logic and electrolysis process of the electrolysis crane, including establishing PLC hardware module configuration, writing PLC ladder diagrams, compiling PLC I / O variables, and establishing DB data blocks to achieve the electrolysis crane's reproduction of the electrolysis process behavior logic;

[0026] Step 2.4: Different control programs are triggered according to different instructions in the PLC program of the electrolytic crane, so as to realize the operating behavior control of the trolley mechanism, the carriage mechanism and the lifting mechanism.

[0027] Step 2.5: The absolute addresses of the I / O variables corresponding to the trolley, car, hoist and gripper are encapsulated in scripts, and timers are set for some workstations by simulating the time observed and recorded by actual workers. The operating behaviors of the encapsulated components are combined in an orderly manner by reading the PLC program through the script language, thus forming an interactive logical model for the electrolytic machining process.

[0028] Step 2.6: The mathematical expression of the interactive logic model is as follows:

[0029] LM={DCI,U} (4)

[0030] U={V1,V2,V3,V4,...,V n} (5)

[0031] V=<XC,X P ,Y P ,Z P ,X R ,Y R ,Z R > (6)

[0032] Where LM represents the interactive logic model; DCI represents the data communication interface; U represents the operation logic of the electrolytic vehicle; V represents the motion behavior of each component of the electrolytic vehicle; XC represents the motion state of each component of the electrolytic vehicle; X P Represents the X-axis translation movement of the component; Y P Represents the Y-axis translation movement of the component; Z P Represents the Z-axis translation movement of the component; X R Represents the X-axis rotation of the component; Y R Represents the Y-axis rotation of the component; Z R Represents the Z-axis rotational motion of the component.

[0033] Specifically, the PLC ladder diagram is the core of the PLC control system, responsible for managing and executing all PLC programs, including the main program, all OB blocks, all subroutines and all data blocks;

[0034] Specifically, the step 3) is as follows:

[0035] The electrolytic crane digital twin model communicates with the virtual device, and establishes communication between the TIA Portal virtual device and the PLC program through PLCSIM Advanced to obtain operation data;

[0036] The process of driving the electrolysis crane digital twin model through operation data and realizing real-time linkage with the virtual equipment includes:

[0037] Step 3.1: Import the HslCommunication plug-in into the Plugin section of Unity3D, and develop the Visual Studio and TIA Portal communication scripts through the S7 protocol to establish a communication connection between PLCSIM Advanced and Unity3D.

[0038] Step 3.2: In the TIA Portal, turn off optimized block access for accessing data blocks, adjust the access level in protection to: Full access; check Allow PUT / GET connections, and select the S7 communication block;

[0039] Step 3.3: Use PLCSIM Advanced to establish communication between the electrolysis crane and PLC, compile the PLC program and download it to the device, then start the PLC to find the corresponding PN / IE interface and perform at least one simulation test to obtain the simulation results.

[0040] step3.4: According to the S7 protocol between Unity3D and PLC, the absolute address of the I / O variable corresponding to the job data is encapsulated through the script file to complete the reading and writing of the job data in Unity3D, so as to realize the real-time linkage between the job data-driven electrolysis driving digital twin model and the virtual device.

[0041] Specifically, the UI visualization interface displays the operation data in numerical form, and the staff detects the operating frequency, motor speed, motor current, operating speed and operating position of the operating mechanism during the operation of the electrolytic crane through the UI visualization interface;

[0042] The interactive control performed by the interactive panel includes the rising and falling of the main lifting and hoisting mechanisms; the forward and backward movement of the trolley mechanism; the left and right movement of the carriage mechanism; the emergency stop of the electrolysis process; and the position restoration of the electrolysis crane.

[0043] The beneficial effects of the present invention are as follows: the present invention can digitize the actual operating status and working parameters of the electrolytic crane, and display them through the human-computer interaction panel. Through the visual human-computer interaction panel, the electrolytic crane can be simulated and emulated in a virtual environment. In addition, the digital twin technology can also provide more intuitive and reliable work guidance and decision-making support for the electrolytic crane operator, so that it can more accurately grasp the operation of the electrolytic crane and discover and solve problems in a timely manner. This not only improves the work efficiency of the workers, but also increases work safety, and provides a more convenient and intelligent solution for the operation and management of the electrolytic crane. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is the overall design flow chart of the electrolytic crane digital twin system;

[0045] Figure 2 It is a flow chart of lightweight processing of electrolytic driving geometry model;

[0046] Figure 3 This is the architecture diagram of the electrolysis driving digital twin system based on Unity3D;

[0047] Figure 4 This is the PLC program structure diagram of the electrolytic crane;

[0048] Figure 5 It is the process of constructing the interactive logic model of electrolytic driving;

[0049] Figure 6 It is the visual human-computer interaction interface of the electrolytic crane digital twin system. DETAILED DESCRIPTION

[0050] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0051] Example 1: Figure 1 As shown in the figure, a digital twin system of electrolysis driving based on Unity3D includes

[0052] The digital twin model of the electrolytic crane includes a visualized geometric model of the electrolytic crane and an interactive logical model of the electrolytic crane. The visualized geometric model of the electrolytic crane uses graphics knowledge and mechanics knowledge to achieve digital mapping of the geometric properties of the electrolytic crane equipment to achieve visualization of the equipment object. The interactive logical model of the electrolytic crane describes the production logic and electrolysis process of the electrolytic crane during the electrolysis process. By encapsulating and calling the logical model, the electrolytic crane can reproduce the behavior logic of the electrolysis process.

[0053] The virtual device based on TIA Portal communicates with the electrolysis crane digital twin model and the visual human-machine interaction panel respectively;

[0054] The visual human-machine interaction panel includes a UI visual interface and an interactive panel. The UI visual interface drives the virtual scene under the Unity3D virtual engine through the operation data, and the operating parameters of various equipment in the electrolysis crane are mapped in real time in the visual interactive panel through the Xcharts plug-in and UI Text components in Unity3D. The interactive panel interactively controls the operating mechanism of the electrolysis crane based on the Button option of the UGUI component in Unity3D.

[0055] A method for building a digital twin system of an electrolytic vehicle based on Unity3D, comprising the following steps:

[0056] 1) Build a digital twin model of the electrolytic vehicle that includes a visualized geometric model and an interactive logic model;

[0057] 2) Build a virtual device based on TIA Portal;

[0058] 3) Based on the digital twin technology, the digital twin model of the electrolysis crane is connected to the virtual device to obtain the operation data, and the digital twin model of the electrolysis crane and the virtual device are driven to work in real time through the operation data;

[0059] 4) Build a visual human-computer interaction panel based on the Unity3D platform, including two parts: the UI visualization interface and the interaction panel, and at the same time connect the virtual device with the visual human-computer interaction panel for communication.

[0060] Using Unity3D to build the electrolytic crane digital twin model can make full use of the professionalism of Unity3D as a game engine, because it has rich three-dimensional model processing and real-time rendering functions. The UI components in Unity3D can create various UI elements, and allow animation effects to be added to UI elements, which is conducive to user interface design and improves development efficiency and quality. The present invention shares the construction of the digital twin system to different technical fields, aiming to reduce the coupling degree of the system, and uses Siemens PLC to communicate with the electrolytic crane digital twin model to build the electrolytic crane digital twin system, which can better realize the flexibility and maintainability of the system.

[0061] Furthermore, the process of building a virtual device based on the TIA Portal includes: establishing a PLC hardware module configuration S7-1500 series PLC, the CPU model is 1515-2PN, three input expansion switch modules DI 32*24VDC HF, and one output expansion switch module DQ 32*24VDC / 0.5; setting the IP address and subnet mask of the PLC through PLCSIM Advanced, and the IP address and subnet mask are consistent with the CPU of the PLC host equipment to establish PUT / GET communication with the TIA Portal to complete the construction of the virtual device on the TIA Portal.

[0062] Furthermore, the construction process of the electrolytic driving visualization geometric model is as follows:

[0063] Step 1.1: By analyzing the physical structure of the electrolytic crane, collect the shape, size, spatial position, assembly relationship, material, and color of the on-site electrolytic crane;

[0064] Step 1.2: Use SolidWorks 3D modeling software to build the geometric model of the electrolytic crane: geometric modeling of the trolley, trolley, hanger, gripper, cab, crane main beam, trolley drive, electrolytic cell, trolley frame, liquid receiving tray, trolley drive and accessory parts;

[0065] Step 1.3: In order to ensure the post-rendering of the 3D model, choose to export the STEP file of the electrolytic vehicle geometry model, import the STEP file into 3dsMax, use the Polygon Cruncher lightweight plug-in in 3dsMax to cut the number of vertices and faces in the electrolytic vehicle geometry model, complete the lightweight processing of the electrolytic vehicle geometry model and export the FBX file;

[0066] step1.4: Import the FBX file into the Unity3D engine, restore the electrolysis scene, use VisualStudio to develop a simulation data-driven script, realize the detailed characterization of the electrolysis vehicle's geometric information, and complete the construction of the electrolysis vehicle's visual geometric model.

[0067] By constructing a visual geometric model of the electrolytic crane, the "twin" of the digital twin model of the electrolytic crane is realized in terms of visual senses and structural relationships; by conducting a detailed analysis of the production logic solution and electrolysis process of the electrolytic crane, starting from the operating logic of the electrolytic crane, an interactive logic model is constructed in the form of script encapsulation to achieve the "twin" of the production logic in the electrolytic processing process of the electrolytic crane, and complete the construction of the digital twin model of the electrolytic crane.

[0068] In order to reduce the huge performance overhead of the electrolytic driving visualization geometry model during the development process of the Unity3D engine platform, the electrolytic driving geometry model needs to be lightweight. The lightweight processing of the electrolytic driving geometry model is mainly to reduce the number of points, lines and surfaces in the electrolytic driving geometry model while ensuring the accuracy of the visualization model and the integrity of the model elements.

[0069] The electrolytic driving geometric model should meet the following requirements:

[0070] 1) The amount of processed electrolytic driving geometry model data is small;

[0071] 2) The geometric model of the electrolytic vehicle obtained after processing must ensure that the details are not lost or deformed. Specifically, there should be no deformation or cavity inside or outside the geometric model of the electrolytic vehicle;

[0072] 3) The processed electrolytic vehicle geometric model should retain information such as size, assembly relationship and material properties that are consistent with the physical entity.

[0073] The Polygon Cruncher lightweight plug-in can trim the number of vertices and faces in the electrolytic vehicle geometry model in 3ds Max according to requirements. Using the Polygon Cruncher lightweight plug-in can not only ensure the quality of the electrolytic vehicle geometry model, but also improve the rendering efficiency of the electrolytic vehicle geometry model. Even at a high optimization rate, the Polygon Cruncher lightweight plug-in can retain all the details in the electrolytic vehicle geometry model. The specific lightweight processing process is as follows: Figure 2 shown.

[0074] Furthermore, if Figure 5 As shown in the figure, the construction process of the interactive logic model of electrolytic driving is as follows:

[0075] Step 2.1: Clarify the processing tasks of the electrolytic crane equipment. In the actual production process, the electrolytic crane equipment is mainly responsible for transporting the interlaced anode and cathode plates to the electrolytic cell, which starts the electrolysis process. When the electrolysis cycle is over, the electrolytic crane will lift the plate assembly to the cathode plate stripping unit, strip the cathode plate and transport it to the finished product area outside the electrolysis workshop, and transport the anode plate to the residual anode stacking area for unified processing;

[0076] Step 2.2: The electrolytic machining process is completed by the cooperation of different active parts, so it is necessary to organize and classify the basic categories of the movement behaviors of different active parts. Use the nested "parent-child nodes" to organize and divide the internal structure and visual geometric model of the electrolytic crane, that is, when the "parent object" moves, the "child object" can only follow the "parent object" for local movement; when the "child object" moves, the movement of the "child object" will not affect the movement of the "parent object".

[0077] Step 2.3: PLC modeling is performed according to the production logic and electrolysis process of the electrolysis crane. The electrolysis crane is a highly automated integrated device. The automatic control of the electrolysis crane is mainly achieved through the PLC program, including establishing PLC hardware module configuration, writing PLC ladder diagrams, compiling PLC I / O variables, and establishing DB data blocks to achieve the electrolysis crane's reproduction of the electrolysis process behavior logic;

[0078] Step 2.4: Different control programs are triggered according to different instructions in the PLC program of the electrolytic crane, so as to realize the operating behavior control of the trolley mechanism, the carriage mechanism and the lifting mechanism.

[0079] Step 2.5: The absolute addresses of the I / O variables corresponding to the trolley, car, hoist and gripper are encapsulated in scripts, and timers are set for some workstations by simulating the time observed and recorded by actual workers. The operating behaviors of the encapsulated components are combined in an orderly manner by reading the PLC program through the script language, thus forming an interactive logical model for the electrolytic machining process.

[0080] Step 2.6: The mathematical expression of the interactive logic model is as follows:

[0081] LM={DCI,U} (7)

[0082] U={V1,V2,V3,V4,...,V n} (8)

[0083] V=<XC,X P ,Y P ,Z P ,X R ,Y R ,Z R > (9)

[0084] Where LM represents the interactive logic model; DCI represents the data communication interface; U represents the operation logic of the electrolytic vehicle; V represents the motion behavior of each component of the electrolytic vehicle; XC represents the motion state of each component of the electrolytic vehicle; X P Represents the X-axis translation movement of the component; Y P Represents the Y-axis translation movement of the component; Z P Represents the Z-axis translation movement of the component; X R Represents the X-axis rotation of the component; Y R Represents the Y-axis rotation of the component; Z R Represents the Z-axis rotational motion of the component.

[0085] Furthermore, the PLC ladder diagram is the core of the PLC control system, responsible for managing and executing all PLC programs, including the main program, all OB blocks, all subroutines and all data blocks;

[0086] Furthermore, the step 3) is specifically as follows:

[0087] The electrolytic crane digital twin model communicates with the virtual device, and establishes communication between the TIA Portal virtual device and the PLC program through PLCSIM Advanced to obtain operation data;

[0088] The process of driving the electrolysis crane digital twin model through operation data and realizing real-time linkage with the virtual equipment includes:

[0089] Step 3.1: Import the HslCommunication plug-in into the Plugin section of Unity3D, and develop the Visual Studio and TIA Portal communication scripts through the S7 protocol to establish a communication connection between PLCSIM Advanced and Unity3D.

[0090] Step 3.2: In the TIA Portal, turn off optimized block access for accessing data blocks, adjust the access level in protection to: Full access; check Allow PUT / GET connections, and select the S7 communication block;

[0091] Step 3.3: Use PLCSIM Advanced to establish communication between the electrolysis crane and PLC, compile the PLC program and download it to the device, then start the PLC to find the corresponding PN / IE interface and perform at least one simulation test to obtain the simulation results.

[0092] step3.4: According to the S7 protocol between Unity3D and PLC, the absolute address of the I / O variable corresponding to the job data is encapsulated through the script file to complete the reading and writing of the job data in Unity3D, so as to realize the real-time linkage between the job data-driven electrolysis driving digital twin model and the virtual device.

[0093] Furthermore, the interactivity of workers in the electrolytic processing process is a necessary basis for realizing the monitoring of the electrolytic production process. The UI visualization interface displays the operation data in numerical form, and the workers detect the operating frequency, motor speed, motor current, and operating position of the operating mechanism during the operation of the electrolytic crane through the UI visualization interface;

[0094] The interactive control of the interactive panel includes the rise and fall of the main lifting and hoist lifting mechanisms; the forward and backward movement of the trolley mechanism; the left and right movement of the carriage mechanism; the emergency stop of the electrolysis process; and the position recovery of the electrolysis crane. This not only improves the work efficiency of workers, but also increases work safety, and provides a more convenient and intelligent solution for the operation and management of the electrolysis crane.

[0095] Furthermore, the interactive panel is adjusted to an appropriate size and integrated with the UI visualization interface to complete the construction of the visual human-computer interaction panel. The specific effect is as follows: Figure 6 shown.

[0096] Figure 3 The figure shows the architecture diagram of the electrolytic crane digital twin system based on Unity3D. PLC modeling is performed based on the electrolytic crane digital twin model. The PLC modeling process includes:

[0097] Establish PLC hardware module configuration S7-1500 series PLC, CPU model is 1515-2PN, input expansion switch module DI 32*24VDC HF three pieces, output expansion switch module DQ 32*24VDC / 0.5 one piece;

[0098] Use PLCSIM Advanced to set the IP address and subnet mask of the PLC. The IP address and subnet mask should be consistent with the CPU of the PLC host to establish PUT / GET communication with the TIA Portal.

[0099] Download the written PLC program to the device and compile it without error; start the CPU and go online, find the corresponding PN / IE interface and perform at least one simulation test to obtain the simulation result. Enable monitoring to monitor the connectivity of the PLC program in real time;

[0100] Import the HslCommunication plug-in into the Plugin section of Unity3D, use Visual Studio to develop a communication script with TIA Portal, and establish a communication connection between PLCSIM Advanced and Unity3D.

[0101] According to the S7 protocol between Unity3D and PLC, the absolute address of the I / O variable corresponding to the job data is encapsulated through the script file, and the reading and writing of the job data in Unity3D are completed, so as to realize the real-time linkage between the job data-driven electrolysis driving digital twin model and the virtual equipment;

[0102] The electrolytic crane is a highly automated integrated device that mainly uses PLC programs to grasp and move the anode and cathode plates. The PLC of the electrolytic crane has control programs for multiple subsystems. Different instructions trigger different control programs to control the motion behavior of different mechanisms. The specific composition of the electrolytic crane PLC program is as follows: Figure 4 shown.

[0103] In order to clearly and accurately describe the production logic of the electrolytic machining process, the present invention proposes to construct a logical model of the electrolytic machining process based on the operating logic of the electrolytic crane, thereby realizing the "twin" of the digital twin model of the electrolytic machining process and the operating logic of the physical entity.

[0104] The specific implementation modes of the present invention are described in detail above in conjunction with the accompanying drawings, but the present invention is not limited to the above implementation modes, and various changes can be made within the knowledge scope of ordinary technicians in this field without departing from the purpose of the present invention.

Claims

1. A digital twin system for electrolysis crane based on Unity3D, characterized by: include The digital twin model of the electrolytic crane includes a visualized geometric model of the electrolytic crane and an interactive logical model of the electrolytic crane. The visualized geometric model of the electrolytic crane uses graphics knowledge and mechanics knowledge to achieve digital mapping of the geometric properties of the electrolytic crane equipment to achieve visualization of the equipment object. The interactive logical model of the electrolytic crane describes the production logic and electrolysis process of the electrolytic crane during the electrolysis process. By encapsulating and calling the logical model, the electrolytic crane can reproduce the behavior logic of the electrolysis process. The virtual device based on TIA Portal communicates with the electrolysis crane digital twin model and the visual human-machine interaction panel respectively; The visual human-computer interaction panel includes a UI visual interface and an interactive panel. The UI visual interface drives the virtual scene under the Unity3D virtual engine through the operation data, and maps the operating parameters of various equipment in the electrolysis crane in real time in the visual interactive panel through the Xcharts plug-in and UI Text component in Unity3D. The interactive panel interactively controls the operating mechanism of the electrolysis crane based on the Button option of the UGUI component in Unity3D.

2. A method for building a digital twin system of an electrolytic crane based on Unity3D, characterized in that: The steps include: 1) Build a digital twin model of the electrolytic vehicle that includes a visualized geometric model and an interactive logic model; 2) Build a virtual device based on TIA Portal; 3) Based on the digital twin technology, the digital twin model of the electrolysis crane is connected to the virtual device to obtain the operation data, and the digital twin model of the electrolysis crane and the virtual device are driven to work in real time through the operation data; 4) Build a visual human-computer interaction panel based on the Unity3D platform, including two parts: the UI visualization interface and the interaction panel, and at the same time connect the virtual device with the visual human-computer interaction panel for communication.

3. The method for building a digital twin system of an electrolytic vehicle based on Unity3D according to claim 2, characterized in that: The process of building a virtual device based on the TIA Portal includes: establishing the PLC hardware module configuration S7-1500 series PLC, the CPU model is 1515-2PN, three input expansion switch modules DI 32*24VDC HF, and one output expansion switch module DQ 32*24VDC / 0.5; setting the IP address and subnet mask of the PLC through PLCSIM Advanced. The IP address and subnet mask are consistent with the CPU of the PLC host equipment to establish PUT / GET communication with the TIA Portal to complete the construction of the virtual device on the TIA Portal.

4. The digital twin system of electrolysis crane based on Unity3D and the construction method thereof according to claim 2 is characterized in that: The construction process of the electrolytic driving visualization geometric model is as follows: Step 1.1: By analyzing the physical structure of the electrolytic crane, collect the shape, size, spatial position, assembly relationship, material, and color of the on-site electrolytic crane; Step 1.2: Use SolidWorks 3D modeling software to build the geometric model of the electrolytic crane: geometric modeling of the trolley, trolley, hanger, gripper, cab, crane main beam, trolley drive, electrolytic cell, trolley frame, liquid receiving tray, trolley drive and accessory parts; Step 1.3: Export the STEP file of the electrolytic vehicle geometry model, import the STEP file into 3dsMax, use the PolygonCruncher lightweight plug-in in 3dsMax to trim the number of vertices and faces in the electrolytic vehicle geometry model, complete the lightweight processing of the electrolytic vehicle geometry model and export the FBX file; step1.4: Import the FBX file into the Unity3D engine, restore the electrolysis scene, use Visual Studio to develop a simulation data-driven script, achieve detailed characterization of the electrolysis vehicle's geometric information, and complete the construction of the electrolysis vehicle's visual geometric model.

5. The digital twin system of electrolysis crane based on Unity3D and the construction method thereof according to claim 2, characterized in that: The construction process of the interactive logic model of electrolytic driving is as follows: Step 2.1: Clarify the processing tasks of electrolytic crane equipment; Step 2.2: Use the nested "parent-child nodes" method to organize and divide the internal structure and visual geometric model of the electrolytic vehicle. That is, when the "parent object" moves, the "child object" can only follow the "parent object" to move locally; when the "child object" moves, the movement of the "child object" will not affect the movement of the "parent object"; Step 2.3: PLC modeling is performed according to the production logic and electrolysis process of the electrolysis crane, including establishing PLC hardware module configuration, writing PLC ladder diagrams, compiling PLC I / O variables, and establishing DB data blocks to achieve the electrolysis crane's reproduction of the electrolysis process behavior logic; Step 2.4: Different control programs are triggered according to different instructions in the PLC program of the electrolytic crane, so as to realize the operation behavior control of the trolley mechanism, the carriage mechanism and the lifting mechanism; Step 2.5: The absolute addresses of the I / O variables corresponding to the trolley, car, spreader, and gripper are encapsulated in scripts, and timers are set for some workstations by simulating the time observed and recorded by actual workers. The running behaviors of the encapsulated components are combined in an orderly manner by reading the PLC program through the script language, thus forming an interactive logic model for the electrolytic machining process; Step 2.6: The mathematical expression of the interactive logic model is as follows: LM={DCI,U} (1) U={V1,V2,V3,V4,...,V n } (2) V=<XC,X P ,Y P ,Z P ,X R ,Y R ,Z R > (3) Where LM stands for interactive logic model; DCI stands for data communication interface; U represents the operation logic of the electrolytic vehicle; V represents the movement behavior of each component of the electrolytic vehicle; XC represents the movement state of each component of the electrolytic vehicle; X P Represents the X-axis translation movement of the component; Y P Represents the Y-axis translation movement of the component; Z P Represents the Z-axis translation movement of the component; X R Represents the X-axis rotation of the component; Y R Represents the Y-axis rotation of the component; Z R Represents the Z-axis rotational motion of the component.

6. According to claim 5, a Unity3D-based electrolysis driving digital twin system and its construction method, characterized in that: The PLC ladder diagram is the core of the PLC control system and is responsible for managing and executing all PLC programs, including the main program, all OB blocks, all subroutines and all data blocks.

7. According to claim 2, a Unity3D-based electrolysis driving digital twin system and its construction method, characterized in that: The step 3) is specifically as follows: The electrolysis crane digital twin model communicates with the virtual device, and establishes communication between the TIAPortal virtual device and the PLC program through PLCSIM Advanced to obtain operation data; The process of driving the electrolysis crane digital twin model through operation data and realizing real-time linkage with the virtual equipment includes: Step 3.1: Import the HslCommunication plug-in into the Plugin section of Unity3D, and develop the Visual Studio and TIA Portal communication scripts through the S7 protocol to establish the communication connection between PLCSIM Advanced and Unity3D; Step 3.2: In the TIA Portal, turn off optimized block access for accessing data blocks, adjust the access level in protection to: Full access; check Allow PUT / GET connections, and select the S7 communication block; Step 3.3: Use PLCSIM Advanced to establish communication between the electrolysis crane and the PLC, compile the PLC program and download it to the device, then start the PLC to find the corresponding PN / IE interface and perform at least one simulation test to obtain the simulation results; step3.4: According to the S7 protocol between Unity3D and PLC, the absolute address of the I / O variable corresponding to the job data is encapsulated through the script file to complete the reading and writing of the job data in Unity3D, so as to realize the real-time linkage between the job data-driven electrolysis driving digital twin model and the virtual device.

8. According to claim 2, a Unity3D-based electrolysis driving digital twin system and its construction method, characterized in that: The UI visualization interface displays the operation data in numerical form, and the staff detects the operating frequency, motor speed, motor current, operating position and operating speed of the operating mechanism during the operation of the electrolytic crane through the UI visualization interface; The interactive control performed by the interactive panel includes the raising and lowering of the main lifting and hoisting mechanisms; The trolley mechanism moves forward and backward; the carriage mechanism moves left and right; the electrolysis process stops suddenly; the electrolysis crane restores its position.

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