Flat glass production line virtual debugging method and system, storage medium and equipment

Abstract

The invention provides a virtual debugging method and system for a plate glass production line, a storage medium and equipment, and the method comprises the following steps: carrying out the system analysis and modular design of the plate glass production line, and determining the overall layout of the plate glass production line and the design variables of all modules; building a plate glass production line three-dimensional model based on the overall layout and the design variables of the modules; building a communication channel among the three-dimensional model of the plate glass production line, corresponding physical entity equipment and an MES system based on a digital twinning technology, and obtaining a virtual simulation result of the plate glass production line; and adjusting design variables of the three-dimensional model of the plate glass production line based on the virtual simulation result. According to the virtual debugging method for the plate glass production line, each link of the production line can be accurately simulated and optimized in a virtual environment, so that potential problems are eliminated before actual production, and the production efficiency and the product quality are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of virtual debugging, and in particular relates to a virtual debugging method, system, storage medium and equipment for a flat glass production line. Background Art

[0002] Digital twin technology is committed to achieving high-fidelity mapping of physical entities in a virtual environment through elements such as the sensory data of physical entities and heterogeneous virtual models. This technology is widely used in many fields such as workshop management, product design and assembly. As a highly integrated production line, the glass manufacturing industry requires precise control of cutting systems, waiting, steering, grabbing and other mechanisms to optimize coordination and improve overall efficiency. In the absence of digital assistance, product design often requires multiple iterations, which not only consumes a lot of resources, but may also delay delivery time. In addition, the difficulty of parallel design of equipment structure design and electrical control design further affects the project cycle. Before the equipment is put into use, some design defects such as the rationality of key process parameters such as equipment beat are difficult to discover in the early stage. However, in the existing technology, how to improve the fit between virtual space and physical space, realize high-fidelity simulation data collection and rapid interaction with real equipment has become a new technical challenge.

[0003] Previous simulation designs mainly focused on the appearance and physical properties of production equipment, but these models cannot simultaneously reflect the uncertain interference factors and their impact that may occur during the production process. This means that the accuracy of the relevant simulations must be ensured after repeated testing and modification in actual production. Existing production line design and simulation usually rely on the experience of engineers and perform local simulations on specific production equipment sections, resulting in incomplete simulation data, lack of consistency and synchronization between information and physical models, and inability to accurately reflect the production situation of the entire line, resulting in a large gap between the simulation results and the actual situation.

[0004] Therefore, providing a virtual debugging method suitable for a flat glass production line to solve the above problems has become a technical problem that needs to be solved urgently in this field. Summary of the invention

[0005] In view of the shortcomings of the prior art mentioned above, the purpose of the present invention is to provide a virtual debugging method, system, storage medium and equipment for a flat glass production line. Through the application of digital twin technology and simulation software, it is possible to simulate and optimize the production process in a virtual environment and improve the design efficiency and operation performance of the production line.

[0006] In a first aspect, the present invention provides a virtual debugging method for a flat glass production line, the method comprising the following steps:

[0007] Conduct system analysis and modular design on the flat glass production line to determine the overall layout of the flat glass production line and the design variables of each module;

[0008] Building a three-dimensional model of a flat glass production line based on the overall layout and design variables of each module;

[0009] Based on the digital twin technology, a three-dimensional model of the flat glass production line and corresponding physical entity equipment and a communication channel between the MES system are constructed to obtain a virtual simulation result of the flat glass production line;

[0010] The design variables of the three-dimensional model of the flat glass production line are adjusted based on the virtual simulation results.

[0011] In an implementation of the first aspect, performing system analysis and modular design on a flat glass production line to determine the overall layout of the flat glass production line and design variables of each module includes the following steps:

[0012] Analyze the production requirements and overall process flow of the flat glass production line to obtain analysis results;

[0013] Based on the analysis results, the spatial layout and functional modules of the flat glass production line are designed, and the design variables of the functional modules are determined.

[0014] In an implementation of the first aspect, the functional modules include a production equipment module, a material source module, an acceleration roller module, a drop plate roller module, a swing roller module, a group roller module, a rotary lifting platform module, and a stacker module.

[0015] In an implementation of the first aspect, constructing a three-dimensional model of a flat glass production line based on the overall layout and design variables of each module comprises the following steps:

[0016] The functional modules are three-dimensionally modeled based on simulation software, and control scripts are written according to the motion logic and process requirements between the functional modules;

[0017] Based on the time sequence, space sequence and logic characteristics of the process corresponding to the flat glass production line, the corresponding algorithms and processes are encapsulated to form various virtual function modules.

[0018] In an implementation of the first aspect, constructing a three-dimensional model of the flat glass production line and a communication channel between corresponding physical entity equipment and an MES system based on the digital twin technology, and obtaining a virtual simulation result of the flat glass production line includes the following steps:

[0019] Configure corresponding communication data interfaces and control ports for each functional module, and construct a real-time data communication channel between the three-dimensional model of the flat glass production line and the corresponding physical entity equipment and the MES system;

[0020] The three-dimensional model of the flat glass production line and the corresponding physical entity equipment are run simultaneously to obtain the virtual simulation result of the flat glass production line.

[0021] In an implementation of the first aspect, adjusting the design variables of the three-dimensional model of the flat glass production line based on the virtual commissioning result comprises the following steps:

[0022] Analyzing the virtual simulation results, and modifying the three-dimensional model of the flat glass production line based on the virtual simulation results;

[0023] Run the modified 3D model of the flat glass production line again to obtain the optimal debugging results.

[0024] In an implementation of the first aspect, based on the optimal debugging result, the production order information and the production schedule in the MES system are updated to achieve synchronous optimization with the three-dimensional model of the flat glass production line.

[0025] In a second aspect, the present invention provides a virtual debugging system for a flat glass production line, the system comprising a layout design module, a model building module, a virtual simulation module and a model optimization module;

[0026] The layout design module is used to perform system analysis and modular design on the flat glass production line, and determine the overall layout of the flat glass production line and the design variables of each module;

[0027] The model building module is used to build a three-dimensional model of a flat glass production line based on the overall layout and design variables of each module;

[0028] The virtual simulation module is used to construct a three-dimensional model of the flat glass production line and a communication channel between corresponding physical entity equipment and the MES system based on the digital twin technology to obtain a virtual simulation result of the flat glass production line;

[0029] The model optimization module is used to adjust the design variables of the three-dimensional model of the flat glass production line based on the virtual simulation results.

[0030] In a third aspect, the present invention provides an electronic device, the electronic device comprising: a processor and a memory;

[0031] The memory is used to store computer programs;

[0032] The processor is used to execute the computer program stored in the memory, so that the electronic device executes the above-mentioned virtual debugging method of the flat glass production line.

[0033] In a fourth aspect, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by an electronic device, implements the above-mentioned virtual debugging method for a flat glass production line.

[0034] As described above, the flat glass production line virtual debugging method, system, storage medium and electronic device of the present invention have the following beneficial effects:

[0035] The flat glass production line virtual debugging method, system, storage medium and electronic device of the present invention break the traditional barriers between information data and physical models, and realize the deep linkage between virtual and actual operations. Specifically, it has the following beneficial effects:

[0036] The present invention aims at the general characteristics of flat glass production line equipment, deeply analyzes the basic functions and characteristics of process operations, and constructs a general equipment model library through abstract processing of process movement mode, algorithm and action trigger mechanism. Each module in the model library is equipped with a flexible data interface, which can adapt to the production requirements of different orders. The parametric design method greatly simplifies the creation process of the digital twin model. Only relevant parameters need to be adjusted, which greatly shortens the design cycle and improves the flexibility of the design.

[0037] With the strong support of digital twin technology, the simulation model of the present invention can accurately and in real time map actual production activities in multiple dimensions. By extracting production order information from the manufacturing execution system (MES), the present invention can predict the rationality of different order scheduling and provide scientific scheduling guidance for production personnel, so as to complete order production tasks more efficiently.

[0038] The present invention adopts a joint debugging strategy of physical entities and virtual models on the basis of realizing a close integration of virtual and reality. This strategy takes into account the real-time operating status of the equipment, and simulates the emergencies that may be encountered in actual operation by introducing human interference factors, setting equipment failure rates, etc. This method can not only more accurately predict the impact of equipment failures on the entire production line, but also provide data support for the optimization of production line structure, reduce the number of model modifications, and ensure that better design results are obtained while shortening the design cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a diagram showing the steps of a virtual debugging method for a flat glass production line according to an embodiment of the present invention;

[0040] Figure 2Shown is a flow chart of a virtual debugging method for a flat glass production line according to an embodiment of the present invention;

[0041] Figure 3 Shown is a structural diagram of a virtual debugging method for a flat glass production line according to an embodiment of the present invention;

[0042] Figure 4 Shown is a structural schematic diagram of a virtual debugging system for a flat glass production line according to an embodiment of the present invention;

[0043] Figure 5 It is a schematic structural diagram of an electronic device of the present invention in one embodiment. DETAILED DESCRIPTION

[0044] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.

[0045] It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and thus the drawings only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0046] The present invention designs a virtual debugging method for a flat glass production line. By using digital simulation software, the process parameters of the flat glass production line are imported, a three-dimensional model of the flat glass production line is established, the motion rules of each motion unit are defined, and the process layout of the flat glass production line is completed; the real-time interaction between the production equipment and the digital model is realized based on the control signal of the flat glass production equipment; at the same time, the configuration of the production equipment is jointly debugged with the digital model, and the test and joint debugging results are analyzed and tested to obtain the design deficiencies of the production line, optimize the layout of the production line, and improve the production line rhythm; and the digital model of the flat glass production line is optimized to obtain the optimal result. After completing the simulation verification of the process parameters and equipment operation of the flat glass production line, the PLC hardware signal is combined to drive the movement of each equipment model in the digital model to perform electrical control logic simulation verification of the production line. The present invention constructs a digital model of the flat glass production line, which can realize the rhythm analysis of the key nodes of the production line, optimize the process parameters and the rationality of the device process structure of the production line; it helps electrical engineers to intervene in project development in advance, shorten the on-site debugging time of electrical engineers, and improve the efficiency of project research and development. It can also be used to simulate animation display in the actual production process of the production line.

[0047] The technical solutions in the embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0048] like Figures 1 to 3 As shown, in one embodiment, the flat glass production line virtual debugging method of the present invention includes steps S11 to S14.

[0049] Step S11, perform system analysis and modular design on the flat glass production line to determine the overall layout of the flat glass production line and the design variables of each module. Specifically, the following steps are included:

[0050] Analyze the production requirements and overall process flow of the flat glass production line to obtain analysis results;

[0051] Based on the analysis results, the spatial layout and functional modules of the flat glass production line are designed, and the design variables of the functional modules are determined.

[0052] Specifically, the overall process flow, equipment functions, production requirements, etc. of the flat glass production line are analyzed in detail. Each stage of flat glass production is sorted out in detail, including raw material preparation, melting, forming, cooling, cutting, grinding and inspection. The input, processing and output of each stage are analyzed, as well as the mutual influence and dependency between the stages. The function of each equipment on the production line is analyzed, including its operating principle, performance parameters, maintenance requirements, and how it works in coordination with other equipment. Considering market demand, product specifications, production batches, quality standards and other factors, the production capacity, flexibility and scalability requirements of the production line are analyzed.

[0053] Based on the results of the system analysis, the layout design is carried out. According to the process flow of the production line and the function of the equipment, the spatial layout of the production workshop is rationally planned. This includes determining the location of the equipment, the storage area of ​​raw materials and finished products, the activity path of the operators, etc., to ensure the seamless connection of the production process and the efficient flow of materials. Considering factors such as the size of the equipment, operating characteristics, and maintenance requirements, the equipment arrangement design is carried out. The purpose is to reduce the material handling distance, reduce energy consumption, and improve production efficiency. Ensure that the layout of the production line can make the material flow smoothly, avoid cross-flow and backflow phenomena, and reduce waiting and stagnation time in the production process. Through layout design, optimize equipment utilization and personnel operation efficiency, reduce unnecessary actions and time waste, and maximize production efficiency.

[0054] Furthermore, the functional modules include a production equipment module, a material source module, an acceleration roller module, a drop plate roller module, a swing roller module, a group roller module, a rotary lifting platform module, and a stacker module.

[0055] Based on a detailed combing of the process flow of the entire production line, the production line is divided into several functional modules, and the functions of each module are described in detail to clarify its input, processing and output. According to production requirements, the performance goals of each module are determined, such as output, quality, energy consumption, reliability, etc., and the design variables are further identified, such as identifying parameter variables that affect module performance, such as speed, temperature, pressure, size, shape, etc. Another example is to determine the structural variables of the module, such as equipment layout, material selection, component connection method, etc. Another example is to identify the control variables that affect the operation of the module, such as control system parameter settings, sensor layout, actuator response time, etc. Further select the key design variables, and select the variables that have the greatest impact on module performance as design variables; ensure that the selected variables can be controlled and optimized by design means. Then establish the relationship between the design variables and the performance goals, and verify the relationship between the design variables and the performance goals through experiments to ensure the accuracy of the model. Optimize each design variable to find the best value. Iterate and improve the design according to the optimization results. Then verify the optimization effect of the design variables through simulation or actual testing.

[0056] Through system analysis and layout design, a scientific and reasonable design solution can be provided for the flat glass production line, which not only helps to improve production efficiency and product quality, but also reduces production costs and enhances the market competitiveness of the enterprise.

[0057] Step S12: constructing a three-dimensional model of a flat glass production line based on the overall layout and the design variables of each module. Specifically, the following steps are included:

[0058] The functional modules are three-dimensionally modeled based on simulation software, and control scripts are written according to the motion logic and process requirements between the functional modules;

[0059] Based on the time sequence, space sequence and logic characteristics of the process corresponding to the flat glass production line, the corresponding algorithms and processes are encapsulated to form various virtual function modules.

[0060] Specifically, simulation software is used to digitally model each functional module. Digital modeling is the process of converting the physical entity of the actual production line into a virtual model to facilitate simulation and analysis in a computer environment. The modeling software is NX or Inventor; and the digital model is created using Tecnomatix.

[0061] Step S121: Physical to virtual mapping.

[0062] Use professional simulation software to perform 3D modeling of each production equipment. This includes the equipment's geometry, size, color, and any necessary details. During the modeling process, it is necessary not only to consider the physical appearance of the equipment, but also to define its physical properties, such as mass, material, friction coefficient, etc., to ensure that the virtual model can reflect the characteristics of the actual equipment as realistically as possible. Import the established physical model into the simulation software to achieve the mapping of the physical equipment to the virtual space.

[0063] Step S122: Control script writing.

[0064] After importing the 3D model into the simulation software, the initial state and position of the model need to be set. According to the process flow of the production line and the interaction between the equipment, write the control script. These scripts define the behavior of the equipment during the simulation, such as starting, stopping, accelerating, decelerating, and moving paths. The control script should not only simulate the movement of the equipment, but also consider the response of the equipment under specific conditions, such as fault handling, emergency stop, etc.

[0065] In addition, it is necessary to obtain the commonalities and individualities between the behavior actions of production equipment based on the order information, modify the control script of the digital twin model, and plan the behavior actions of the production equipment so that the glass can be delivered to the designated stacking position.

[0066] Step S133: algorithm and process packaging.

[0067] Time sequence: According to the operation time sequence of the production line, the behavior and control logic of each device are connected in series to form a continuous simulation process.

[0068] Spatial sequence: In the virtual space, the spatial position and movement trajectory of the equipment are arranged according to the layout of the actual production line to ensure that the simulation environment is consistent with the actual production environment.

[0069] Logical features: Encapsulate control logic, process parameters, algorithms, etc. into functional modules. These modules can be simple single-function blocks or complex systems that interact with each other according to specific logical relationships. Encapsulation involves simplifying complex process flows and control logic into a series of manageable and reusable modules. These modules can be tested and optimized individually, facilitating rapid configuration and adjustment between different parts of the production line.

[0070] Further, the remaining modules on the production line are designed:

[0071] Material source module: By obtaining order information from the MES system including size, grade, destination, grouping, etc., a virtual order is created in the digital model based on the obtained order information, and the glass production rhythm is controlled based on the virtual glass pulling speed.

[0072] Accelerating roller: After the virtual order is created in the material source module, the virtual order enters the accelerating roller module to accelerate the separation of the created virtual order from the original glass ribbon.

[0073] Drop plate roller: After the virtual order enters the drop plate roller, it will be classified and processed according to the grade information of the virtual order. If it is a waste plate, it will be dropped and crushed, and the normal order will enter the next production link.

[0074] Downward roller conveyor: The virtual order enters the downward roller conveyor, and is transported to different branches according to the destination information of the order, so that orders with different destinations can be delivered to the designated stacking positions.

[0075] Grouping roller conveyor: The virtual order enters the grouping roller conveyor and waits on the grouping roller conveyor according to the grouping information of the order. It is grouped with the next group of orders and the grouped orders are transported as a conveying unit.

[0076] Rotating lift: The virtual order enters the rotating lift, and the conveying direction of the order is changed according to the rotation information of the order.

[0077] Stacker: The virtual order enters the grabbing roller conveyor, and the stacker grabs the ordered glass from the conveyor roller conveyor to the designated stacking position.

[0078] The above steps can be used to simulate the actual production process, predict production efficiency, optimize production line layout, and even test new process parameters before the product is put into actual production.

[0079] In one embodiment, the model obtains order information from the MES system, including glass size, grade, destination, and grouping requirements. The model creates a virtual order based on this information and sets a virtual glass pulling speed to simulate the actual production cycle. The material source module in the simulation software outputs a virtual glass plate, representing the start of production for a new order. The virtual order is passed from the material source module to the acceleration roller module. On the acceleration roller, the virtual order is separated from the original glass ribbon by acceleration, simulating the acceleration process of the glass plate in actual production. The virtual order enters the drop plate roller, and the model classifies and processes it according to the grade information of the order. If it is a waste plate, the model will perform drop plate crushing processing; if it is a normal order, it will continue to enter the next production link. The virtual order is on the swing roller, and according to the destination information of the order, the model directs the order to different branches. This process ensures that each order can be transported to the correct stacking area. The virtual order arrives at the grouping roller, and the model places the order on the roller for sheeting according to the grouping information. When the next group of orders arrives, the model groups them into a conveying unit. The virtual order is on the rotating lift table, and the model adjusts the conveying direction according to the rotation information of the order. This step ensures that the glass sheets are stacked in the correct direction. The virtual order finally enters the grab roller, and the stacker model grabs the glass sheet from the roller according to the preset program. The stacker places the glass sheet on the designated stacking position, completing the simulation of the entire production process.

[0080] Among them, the behavior of production equipment is analyzed according to order information to distinguish which are common actions common to all orders and which are personalized actions unique to specific orders. This analysis helps us modify the control script of the digital twin model to plan the behavior of production equipment. For example, ensure that the glass is accurately delivered to the designated stacking position according to the order requirements. When processing the production process of flat glass, we abstract the actions of cutting, conveying, waiting for sheets, grouping, rotating, grabbing, etc., and write control scripts to ensure that the behavior logic of the virtual model is completely consistent with the action logic of the actual equipment.

[0081] In order to realize data exchange between the digital model and the MES system, a specific communication protocol is formulated. In this way, the production MES system can store order information in the database, and the production line digital model accesses this information through the ODBC interface. After obtaining the order information, the digital model creates the corresponding virtual order in the material source module, and writes control scripts for each module in the model based on this information to simulate the predetermined production process.

[0082] By setting up a multi-order production mode, different production scenarios can be simulated in a virtual environment to verify which equipment segment the production cycle bottleneck of the flat glass production line occurs in. This method allows the production line cycle to be optimized and production efficiency to be improved by adjusting the process parameters of each device. This simulation process not only helps us identify bottlenecks, but also predicts and verifies the effects of improvement measures, thereby achieving more efficient operations and more optimized production processes in actual production. In this way, we can significantly reduce the adjustment time in actual production and improve the reliability and flexibility of the production line.

[0083] Step S13: construct the three-dimensional model of the flat glass production line and the corresponding physical entity equipment and the communication channel between the MES system based on the digital twin technology to obtain the virtual simulation results of the flat glass production line. The steps include:

[0084] Configure corresponding communication data interfaces and control ports for each functional module, and construct a real-time data communication channel between the three-dimensional model of the flat glass production line and the corresponding physical entity equipment and the MES system;

[0085] The three-dimensional model of the flat glass production line and the corresponding physical entity equipment are run simultaneously to obtain the virtual simulation result of the flat glass production line.

[0086] Specifically, step S13 establishes a communication channel between the production equipment and its virtual model through simulation software, so that the data of the production equipment and the corresponding virtual model can interact in real time; the virtual dynamic model and the physical entity equipment of the production line are run at the same time, and the virtual model is controlled by the actual production equipment control information. The data results of the virtual model operation are fed back to the actual production equipment to realize the configuration test and joint debugging of the production line.

[0087] Step S131, communication data interface design.

[0088] Design standardized data interfaces for each module, including data format, transmission protocol, and communication port. These interfaces will be used for data exchange between virtual devices and manufacturing execution systems (MES) and other devices. Create detailed interface documents to explain the functions, parameters, and calling methods of each interface to facilitate developers and system integrators to understand and implement.

[0089] Step S132: PLC control port configuration.

[0090] Configure the output ports of the PLC (Programmable Logic Controller) in the virtual model to ensure that the actions of the virtual device can be mapped to the output signals of the actual PLC. Generate a list containing all PLC control port information and import it into the simulation model to correctly simulate the control logic of the PLC during the simulation process.

[0091] Step S133: Real-time interaction is established.

[0092] Through simulation software, a real-time data communication channel is established between the production equipment and the virtual model. This involves the implementation of real-time data exchange protocols (such as OPC UA, Modbus, etc.). Ensure that the simulation system can receive and send data in real time to monitor and control the operating status of the virtual equipment.

[0093] Step S134: configuration test and joint debugging.

[0094] Run the virtual dynamic model and the physical entity equipment at the same time to compare and verify the behavior of the two. Use the actual production equipment control information to control the virtual model to ensure that the virtual model can accurately simulate the actions of the actual equipment. Feedback the data results of the virtual model operation to the actual production equipment for closed-loop control testing. This helps to detect and correct deviations in the model and ensure the consistency of the model with the actual equipment. During the joint debugging process, adjust the parameters of the virtual model according to the feedback from the actual equipment to optimize the performance of the model until the behavior of the virtual model is highly consistent with the actual equipment.

[0095] Through real-time interaction and joint debugging, the digital model can not only run independently in the simulation environment, but also be closely integrated with the actual production system, providing strong support for the debugging, optimization and maintenance of the production line. This integration ensures the credibility of the simulation results and provides a solid foundation for the intelligence and automation of the production line.

[0096] In one embodiment, the OPC (OLE for Process Control) server is a middleware that allows different industrial devices and software to communicate through standardized methods. In this process, the OPC server is used to store program variables of the PLC (Programmable Logic Controller). These variables are key parameters for controlling production line equipment, such as roller speed, real-time position of glass, glass flow direction, stacker status, number of pieces to be grabbed, number of pieces to be set, etc. In order for the virtual model to communicate with the PLC, a communication data interface needs to be designed. These interfaces define how to read data from the PLC and how to write data to the PLC. By configuring the PLC output port information of each virtual device, it can be ensured that the virtual model can receive the actual control signal from the PLC. During the configuration process, a list of PLC control port information of the dynamic model of the production line is generated. This list records the PLC port corresponding to each virtual device in detail, providing the necessary information for real-time control. Using digital twin technology, a communication channel is established between the production equipment and its virtual model. In this way, the virtual model can reflect the operating status of the actual equipment in real time, and can also send control instructions to the actual equipment. This real-time interaction is bidirectional, ensuring the synchronization of the behavior of the virtual model and the actual equipment. After the communication channel is established, the virtual dynamic model and the physical equipment of the production line can be run simultaneously. This process is called joint debugging, which allows engineers to test and verify the configuration of the production line without physically operating the actual equipment. Through joint debugging, it is possible to check whether the PLC program and control logic are correct, and whether the virtual model accurately simulates the actions of the actual equipment. Any problems can be discovered and corrected at this stage, thus avoiding possible failures and downtime in actual production.

[0097] This process provides a highly simulated environment by integrating virtual models and actual production equipment to test and optimize the control strategy of the production line, with the ultimate goal of ensuring smooth operation of the production line and improving production efficiency.

[0098] Step S14, adjusting the design variables of the three-dimensional model of the flat glass production line based on the virtual simulation results. The steps include:

[0099] Analyzing the virtual simulation results, and modifying the three-dimensional model of the flat glass production line based on the virtual simulation results;

[0100] Run the modified 3D model of the flat glass production line again to obtain the optimal debugging results.

[0101] Based on the optimal debugging result, the production order information and production scheduling plan in the MES system are updated to achieve synchronous optimization with the three-dimensional model of the flat glass production line.

[0102] Specifically, adjusting the design variables of the three-dimensional model of the flat glass production line based on the test joint debugging results of step S13 is an iterative optimization process, which aims to improve the actual design of the production line through simulation analysis to improve efficiency and performance. First, collect all relevant data in the simulation process, including key performance indicators such as production cycle, equipment utilization, material flow time, and scrap rate. Analyze the collected data to identify bottlenecks, inefficient links, or unreasonable designs in the production process. Diagnose the specific causes of these problems, which may include equipment configuration, process parameter settings, production line layout, etc. Secondly, modify the three-dimensional model of the flat glass production line based on the virtual simulation results: According to the analysis results, determine the design variables that need to be adjusted, such as equipment location, conveying speed, process parameters, etc. In the three-dimensional modeling software, modify the model of the production line accordingly to reflect the adjustment of these design variables. And ensure that all parameters in the simulation model are consistent with the modified design. Run the modified three-dimensional model of the flat glass production line again and perform simulation tests to verify whether the design changes have achieved the expected results. Compare the simulation results before and after the modification to ensure that the new design can improve production efficiency, reduce bottlenecks, and reduce scrap rates. If the simulation results are still not ideal, repeat the above analysis, modification and testing process until the optimal debugging results are obtained. When the simulation results show that the production line operation efficiency has reached the highest level and there are no obvious bottlenecks or problems, it can be considered that the optimal design solution has been found.

[0103] Furthermore, based on the optimal debugging results, the production order information and production schedule in the MES system are updated. That is, the key parameters and production data in the optimal debugging results are synchronized to the MES system. According to the new production line performance, the order information is updated, such as the estimated completion time, resource requirements, etc. The production schedule is adjusted to adapt to the new production line design to ensure that production activities can be carried out efficiently and orderly.

[0104] Through this process, the 3D model of the flat glass production line and the actual production activities are optimized synchronously, which not only improves the performance of the production line, but also enhances the flexibility and responsiveness of the entire production system.

[0105] In one embodiment, the specific steps of the virtual debugging method of the flat glass production line of the present invention are as follows:

[0106] (1) Analyze the production requirements of the flat glass production line, including raw material preparation, melting, forming, cooling, cutting, grinding and inspection. Design the spatial layout and functional modules of the production line and determine the design variables of each module, such as equipment layout, material selection, component connection method, etc.

[0107] (2) Use simulation software (such as NX or Inventor) to perform 3D modeling of the functional modules of the production line. Write control scripts to simulate the movement and behavior of the equipment and adjust the model behavior based on the order information.

[0108] (3) Configure the communication data interface and control port to build a real-time data communication channel between the 3D model and the physical equipment and MES system. Run the 3D model and the physical equipment, perform configuration testing and joint debugging to ensure the consistency between the model and the actual equipment.

[0109] (4) Analyze the virtual simulation results and identify bottlenecks and inefficient links. Modify the design variables of the 3D model, such as equipment location, conveying speed, etc. Rerun the simulation to verify the effect of the design change until the optimal debugging result is obtained. Synchronize the optimal debugging result to the MES system to update the order information and production schedule.

[0110] The present invention aims to introduce an innovative virtual debugging method for a flat glass production line, which adopts a modular design concept and covers multiple key modules such as a material source module, an accelerating roller, a plate-dropping roller, a lowering roller, a grouping roller, a rotary lifting platform, and a stacker. By writing sophisticated control scripts for these modules, the predetermined production process is ensured to be accurately implemented.

[0111] In order to achieve efficient virtual joint debugging, we carefully designed the communication data interface of each module, which not only ensures seamless connection with the manufacturing execution system (MES), but also ensures smooth communication with the programmable logic controller (PLC). This method makes it possible to simulate the actual production process in a virtual environment, thereby verifying the rationality of the production rhythm and the correctness of the control logic.

[0112] The present invention provides a solid support for the layout design and process parameter optimization of the production line. In addition, it allows electrical design engineers to participate in the early stages of equipment development and verify the rationality of the control program in advance. This innovative measure significantly shortens the project cycle and improves overall development efficiency.

[0113] In summary, the present invention not only improves the accuracy and reliability of the flat glass production line design, but also lays a foundation for the optimization of the production process and the efficient operation of the equipment, thereby reducing costs and risks while improving production efficiency.

[0114] The protection scope of the flat glass production line virtual debugging method described in the embodiment of the present invention is not limited to the execution order of the steps listed in this embodiment. All solutions implemented by adding, reducing or replacing steps in the prior art based on the principles of the present invention are included in the protection scope of the present invention.

[0115] An embodiment of the present invention also provides a flat glass production line virtual debugging system, which can implement the flat glass production line virtual debugging method described in the present invention. However, the implementation device of the flat glass production line virtual debugging system described in the present invention includes but is not limited to the structure of the flat glass production line virtual debugging system listed in this embodiment. All structural deformations and replacements of the prior art made according to the principles of the present invention are included in the protection scope of the present invention.

[0116] like Figure 4 As shown, in one embodiment, the flat glass production line virtual debugging system of the present invention includes a layout design module 41 , a model building module 42 , a virtual simulation module 43 and a model optimization module 44 .

[0117] The layout design module 41 is used to perform system analysis and modular design on the flat glass production line, and determine the overall layout of the flat glass production line and the design variables of each module.

[0118] The model building module 42 is connected to the layout design module 41 and is used to build a three-dimensional model of a flat glass production line based on the overall layout and design variables of each module.

[0119] The virtual simulation module 43 is connected to the model construction module 41, and is used to construct a three-dimensional model of the flat glass production line and corresponding physical entity equipment and a communication channel between the MES system based on the digital twin technology to obtain the virtual simulation results of the flat glass production line.

[0120] The model optimization module 44 is connected to the virtual simulation module and is used to adjust the design variables of the three-dimensional model of the flat glass production line based on the virtual simulation results.

[0121] In the several embodiments provided by the present invention, it should be understood that the disclosed system, device or method can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of modules / units is only a logical function division, and there may be other division methods in actual implementation, such as multiple modules or units can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or modules or units, which can be electrical, mechanical or other forms.

[0122] The modules / units described as separate components may or may not be physically separated, and the components displayed as modules / units may or may not be physical modules, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules / units may be selected according to actual needs to achieve the purpose of the embodiments of the present invention. For example, the functional modules / units in the various embodiments of the present invention may be integrated into one processing module, or each module / unit may exist physically separately, or two or more modules / units may be integrated into one module / unit.

[0123] Those of ordinary skill in the art should further appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in terms of function in the above description. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

[0124] The embodiment of the present invention also provides a computer-readable storage medium. A person of ordinary skill in the art can understand that all or part of the steps in the method for implementing the above embodiment can be completed by instructing the processor through a program, and the program can be stored in a computer-readable storage medium, and the storage medium is a non-transitory medium, such as a random access memory, a read-only memory, a flash memory, a hard disk, a solid-state hard disk, a magnetic tape, a floppy disk, an optical disc, and any combination thereof. The above storage medium can be any available medium that can be accessed by a computer or a data storage device such as a server or a data center that includes one or more available media. The available medium can be a magnetic medium (e.g., a floppy disk, a hard disk, a tape), an optical medium (e.g., a digital video disc (DVD)), or a semiconductor medium (e.g., a solid-state disk (SSD)), etc.

[0125] An embodiment of the present invention further provides an electronic device, which includes a processor and a memory.

[0126] The memory is used to store computer programs.

[0127] The memory includes: ROM, RAM, disk, USB flash drive, memory card or CD and other media that can store program codes.

[0128] The processor is connected to the memory and is used to execute the computer program stored in the memory so that the electronic device executes the above-mentioned virtual debugging method for the flat glass production line.

[0129] Preferably, the processor can be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it can also be a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, discrete gates or transistor logic devices, discrete hardware components.

[0130] like Figure 5 As shown, the electronic device of the present invention is in the form of a general computing device. The components of the electronic device may include but are not limited to: one or more processors or processing units 51, a memory 52, and a bus 53 connecting different system components (including the memory 52 and the processing unit 51).

[0131] Bus 53 represents one or more of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, a processor or a local bus using any of a variety of bus architectures. For example, these architectures include but are not limited to Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MAC) bus, Enhanced ISA bus, Video Electronics Standards Association (VESA) local bus and Peripheral Component Interconnect (PCI) bus.

[0132] Electronic devices typically include a variety of computer system readable media. These media can be any available media that can be accessed by the electronic device, including volatile and non-volatile media, removable and non-removable media.

[0133] The memory 52 may include computer system readable media in the form of volatile memory, such as random access memory (RAM) 521 and / or cache memory 522. The electronic device may further include other removable / non-removable, volatile / non-volatile computer system storage media. By way of example only, the storage system 523 may be used to read and write non-removable, non-volatile magnetic media ( Figure 5 not shown, usually called a "hard drive"). Although Figure 5Not shown, a disk drive for reading and writing to a removable non-volatile disk (e.g., a "floppy disk"), and an optical disk drive for reading and writing to a removable non-volatile optical disk (e.g., a CD-ROM, a DVD-ROM, or other optical media) may be provided. In these cases, each drive may be connected to the bus 53 via one or more data medium interfaces. The memory 52 may include at least one program product having a set (e.g., at least one) of program modules that are configured to perform the functions of the various embodiments of the present invention.

[0134] A program / utility 524 having a set (at least one) of program modules 5241 may be stored, for example, in the memory 52, such program modules 5241 including but not limited to an operating system, one or more application programs, other program modules, and program data, each of which or some combination thereof may include an implementation of a network environment. The program modules 5241 generally perform the functions and / or methods of the embodiments described herein.

[0135] The electronic device may also communicate with one or more external devices (e.g., keyboards, pointing devices, displays, etc.), one or more devices that enable a user to interact with the electronic device, and / or any device that enables the electronic device to communicate with one or more other computing devices (e.g., network cards, modems, etc.). Such communication may be performed via input / output (I / O) interface 54. Furthermore, the electronic device may also communicate with one or more networks (e.g., local area networks (LANs), wide area networks (WANs), and / or public networks, such as the Internet) via network adapter 55. Figure 5 As shown, the network adapter 55 communicates with other modules of the electronic device via the bus 53. It should be understood that, although not shown in the figure, other hardware and / or software modules can be used in conjunction with the electronic device, including but not limited to: microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data backup storage systems.

[0136] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by a person of ordinary skill in the art without departing from the spirit and technical concept disclosed by the present invention shall still be covered by the claims of the present invention.

Claims

1. A virtual debugging method for a flat glass production line, characterized in that: The method comprises the following steps: Conduct system analysis and modular design on the flat glass production line to determine the overall layout of the flat glass production line and the design variables of each module; Building a three-dimensional model of a flat glass production line based on the overall layout and design variables of each module; Based on the digital twin technology, a three-dimensional model of the flat glass production line and corresponding physical entity equipment and a communication channel between the MES system are constructed to obtain a virtual simulation result of the flat glass production line; The design variables of the three-dimensional model of the flat glass production line are adjusted based on the virtual simulation results.

2. The virtual debugging method of a flat glass production line according to claim 1, characterized in that: Conducting system analysis and modular design on a flat glass production line to determine the overall layout of the flat glass production line and the design variables of each module includes the following steps: Analyze the production requirements and overall process flow of the flat glass production line to obtain analysis results; Based on the analysis results, the spatial layout and functional modules of the flat glass production line are designed, and the design variables of the functional modules are determined.

3. The virtual debugging method of a flat glass production line according to claim 2, characterized in that: The functional modules include a production equipment module, a material source module, an acceleration roller module, a plate drop roller module, a swing roller module, a group roller module, a rotary lifting platform module, and a stacker module.

4. The virtual debugging method of a flat glass production line according to claim 2, characterized in that: Building a three-dimensional model of a flat glass production line based on the overall layout and the design variables of each module includes the following steps: The functional modules are three-dimensionally modeled based on simulation software, and control scripts are written according to the motion logic and process requirements between the functional modules; Based on the time sequence, space sequence and logic characteristics of the process corresponding to the flat glass production line, the corresponding algorithms and processes are encapsulated to form various virtual function modules.

5. The virtual debugging method of a flat glass production line according to claim 2, characterized in that: Building a three-dimensional model of the flat glass production line and corresponding physical entity equipment and a communication channel between the MES system based on the digital twin technology, and obtaining the virtual simulation results of the flat glass production line includes the following steps: Configure corresponding communication data interfaces and control ports for each functional module, and construct a real-time data communication channel between the three-dimensional model of the flat glass production line and the corresponding physical entity equipment and the MES system; The three-dimensional model of the flat glass production line and the corresponding physical entity equipment are run simultaneously to obtain the virtual simulation result of the flat glass production line.

6. The virtual debugging method of a flat glass production line according to claim 1, characterized in that: Adjusting the design variables of the three-dimensional model of the flat glass production line based on the virtual commissioning results comprises the following steps: Analyzing the virtual simulation results, and modifying the three-dimensional model of the flat glass production line based on the virtual simulation results; Run the modified 3D model of the flat glass production line again to obtain the optimal debugging results.

7. The virtual debugging method of a flat glass production line according to claim 6, characterized in that: Based on the optimal debugging result, the production order information and production scheduling plan in the MES system are updated to achieve synchronous optimization with the three-dimensional model of the flat glass production line.

8. A virtual debugging system for a flat glass production line, characterized in that: The system includes a layout design module, a model building module, a virtual simulation module and a model optimization module; The layout design module is used to perform system analysis and modular design on the flat glass production line, and determine the overall layout of the flat glass production line and the design variables of each module; The model building module is used to build a three-dimensional model of a flat glass production line based on the overall layout and design variables of each module; The virtual simulation module is used to construct a three-dimensional model of the flat glass production line and a communication channel between corresponding physical entity equipment and the MES system based on the digital twin technology to obtain a virtual simulation result of the flat glass production line; The model optimization module is used to adjust the design variables of the three-dimensional model of the flat glass production line based on the virtual simulation results.

9. An electronic device, characterized in that: The electronic device comprises: a processor and a memory; The memory is used to store computer programs; The processor is used to execute the computer program stored in the memory, so that the electronic device executes the flat glass production line virtual debugging method according to any one of claims 1 to 7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the program is executed by an electronic device, the flat glass production line virtual debugging method described in any one of claims 1 to 7 is implemented.

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