Digital twin system framework applied to complex equipment
By providing a standardized digital twin system architecture, the problem of large differences in architecture structures in the existing technology is solved, and functions such as update of digital twin models, failure analysis, exception handling, etc. for complex equipment are realized to meet users' needs for rapid system construction.
Patent Information
- Application Number
- CN202411776153.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-05
- Publication Date
- 2025-03-28
AI Technical Summary
The existing technology lacks a standardized digital twin system architecture, which leads to large differences in the architecture structures of different systems, making it difficult to meet users' needs to quickly build digital twin systems.
It provides a digital twin system architecture applied to complex equipment, including an application layer, a virtual layer, a communication layer and a physical layer for transmitting data from top to bottom through Ethernet. Each layer module includes a physical model module, a data acquisition module, a data processing module, a data transmission module, a data storage module, a digital twin model module, a command editing module and a software tool module.
It realizes correlation and cooperation between different levels, completes the design of the digital twin system, and supports functions such as update of digital twin models, fault analysis, exception handling, real-time status monitoring and equipment operation of complex equipment.
Smart Images
Figure CN119720520A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of digital twin system design, and in particular to a digital twin system architecture applied to complex equipment. Background Art
[0002] Digital twin is a digital image of an actual physical system established in a virtual system. It realizes physical entity status monitoring, fault diagnosis, exception handling and behavior control through real-time data interaction and state synchronization between the physical model and the twin model.
[0003] Modeling is the premise for digital twins to realize physical entity status monitoring, fault diagnosis, exception handling and behavior control, and is the core technology for creating digital twin models. However, as digital twins gradually move from research to implementation, digital twin products applied in various fields have achieved a transition from theory to practice. The requirements and functions of digital twin systems are gradually diversified, and higher requirements are also placed on digital twin systems. However, there is currently no standardized reference for the relevant architecture of how to efficiently and accurately establish a digital twin system. The architecture structures of various digital twin systems vary greatly, making it difficult to meet the actual needs of users at different levels to quickly build digital twin systems.
[0004] Therefore, the prior art needs to be further developed. Summary of the invention
[0005] The purpose of the present invention is to overcome the above-mentioned technical deficiencies and provide a digital twin system architecture applied to complex equipment to solve the problems existing in the prior art.
[0006] In order to achieve the above technical objectives, the present invention provides a digital twin system architecture applied to complex equipment, wherein the system architecture includes an application layer, a virtual layer, a communication layer, and a physical layer for transmitting data through Ethernet from top to bottom, wherein: The physical layer includes a physical model module, a data acquisition module, and a data processing module; Communication layer, including data transmission module and data storage module; Virtual layer, including digital twin model module; The application layer includes the instruction editing module and the software tool module.
[0007] Specifically, the physical model module includes: A complex device physical entity is a mechanical device formed by assembling various actuators that perform specific functions of the complex device, and is a physical entity formed by assembling electronic devices required to achieve specific functions of the complex device on the basis of the mechanical device. The various actuators that perform specific functions of the complex device are composed of specific components; The physical environment required by the physical entity of a complex device to realize its function, wherein the physical environment is the physical space in which the physical entity of the complex device realizes its function and the sum of the physical quantities in the space that can affect the operation process of the physical entity of the complex device.
[0008] Specifically, the data acquisition module includes: The device sensor group and environmental sensor group required to collect multi-source real-time data; The device sensor group is used to collect physical quantities of the operation process of the complex device physical entity, including displacement, velocity, acceleration, voltage, current, pressure, and flow; The environmental sensor group is used to collect physical quantities of the physical environment during the operation of the physical entity of the complex equipment, and the physical quantities of the physical environment include temperature, humidity, pressure, light, and gas content.
[0009] Specifically, the data processing module is preset with an algorithm for filtering, classifying, integrating and detecting anomalies of multi-source real-time data.
[0010] Specifically, the data transmission module includes a data exchange unit, a data transmission protocol unit, an industrial network data transmission protocol unit and a data transmission interface unit, wherein: The data exchange unit includes a receiving data thread for the host computer to receive multi-source real-time data, and a sending data thread for the host computer to send an instruction set to the physical model module; The data transmission protocol unit includes a data transmission protocol used for data exchange between the host computer and the main host, and the data transmission protocol unit includes 5G and TCP; The industrial network data transmission protocol unit includes a data transmission protocol for the physical model module to transmit multi-source real-time data to the host computer and for the physical model module to receive the host computer instruction set, and the data transmission protocol includes CAN and SPI; The data transmission interface unit is used for data transmission between the host computer and the main host, and the data transmission mode includes RS-485, RS-232, and USB.
[0011] Specifically, the data storage module includes: Database interface unit and real-time data database; The database interface unit includes an interactive channel between the system framework and the real-time data database established based on database link technology; The real-time data database is a hierarchical database developed based on MySQL, SQLSERVER or ORACLE database and stores administrator information, multi-source real-time data, exception handling records, operation logs and exception handling methods.
[0012] Specifically, the digital twin model module includes a digital twin model, and the digital twin model includes: Geometric model, including the 3D model of complex equipment, manufacturing information of complex equipment, 3D model update algorithm of complex equipment, and distribution information of sensors and controllers of complex equipment; Simulation models related to complex equipment, including mechanism dynamics simulation model, mechanism kinematics simulation model, hydraulic system simulation model, electrical system simulation model, equipment operation status simulation model and finite element simulation model of complex equipment; Equipment maintenance model, including multi-source real-time data, multidisciplinary analysis model based on complex equipment, fault diagnosis method based on complex equipment, and abnormality handling method based on complex equipment.
[0013] Specifically, the instruction editing layer includes: An instruction editor unit and an instruction set unit, wherein the instruction editor unit includes a device manager and a digital twin system; The digital twin system is used to handle complex equipment anomalies; The device manager is used to perform device operations on complex devices; The instruction set unit includes an exception handling instruction set and a device operation instruction set. The device administrator is used to edit the device operation instruction set, and the digital twin system is used to edit the exception handling instruction set.
[0014] Specifically, the software tool module includes: Software tools for building databases, including MySQL or SQLSERVER or ORACLE; Software tools for building virtual 2D and 3D models, including Solid-works and CAD; Software tools for building simulation models, including AMESim, ADAMS, and ANSYS; Software tools used to implement algorithms, including JAVA and Python.
[0015] Specifically, the application layer is used to implement the functions of the digital twin system, including digital twin model update, fault analysis, exception handling, real-time status monitoring, and equipment operation.
[0016] Specifically, the real-time data database stores device administrator information, multi-source real-time data, exception handling records, operation logs, and exception handling methods; The exception handling record includes the time when the exception occurred, the location where the exception occurred, and the exception handling method; The operation log includes the equipment operation time, equipment operation content, and equipment operator; The exception handling method includes the original exception handling method and the newly added exception handling method under the action of the algorithm; The original exception handling method is the exception handling method that already exists in the database before the system database of the present invention adds the first new exception handling method under the algorithm; The newly added exception handling method under the action of the algorithm is that when an exception is detected in the equipment and the cause of the exception is analyzed through a fault diagnosis method based on complex equipment, the cause of the exception is updated by the exception handling method based on complex equipment to form a new exception handling method. The cause of the exception does not exist in the original database but is a new exception handling method newly stored in the database.
[0017] Beneficial effects: The digital twin system architecture applied to complex equipment described in the present invention proposes a common architecture of the digital twin system, which can be based on the common architecture to achieve association and coordination between different levels, and then complete the design of the digital twin system, and realize the digital twin model update, fault analysis, exception handling, real-time status monitoring, equipment operation and other functions of complex equipment. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 It is a schematic diagram of a digital twin system architecture applied to complex equipment proposed in a specific embodiment of the present invention.
[0019] Figure 2 It is a schematic diagram of data transmission path of a digital twin system architecture applied to complex equipment proposed in a specific embodiment of the present invention.
[0020] Figure 3 It is a database structure applied to the digital twin system architecture proposed in the specific embodiment of the present invention.
[0021] Figure 4 It is a digital twin model update flow chart applied to the digital twin system architecture proposed in a specific embodiment of the present invention.
[0022] Figure 5 It is an exception handling flowchart applied to the digital twin system architecture proposed in the specific embodiment of the present invention.
[0023] Figure 6 It is a fault analysis flowchart applied to the digital twin system architecture proposed in the specific embodiment of the present invention.
[0024] Figure 7 It is a device operation flow chart applied to the digital twin system architecture proposed in a specific embodiment of the present invention. DETAILED DESCRIPTION
[0025] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention is clearly and completely described below in conjunction with the accompanying drawings of the present invention. Based on the embodiments in this application, other similar embodiments obtained by ordinary technicians in this field without making creative work should all fall within the scope of protection of this application. In addition, the directional words mentioned in the following embodiments, such as "up", "down", "left", "right", etc., are only reference to the directions of the accompanying drawings. Therefore, the directional words used are used to illustrate rather than limit the invention.
[0026] The present invention will be further described below in conjunction with the accompanying drawings and preferred embodiments.
[0027] See also Figure 1-7 The present invention provides a digital twin system architecture applied to complex equipment, including: The system architecture includes an application layer, a virtual layer, a communication layer and a physical layer for transmitting data through Ethernet from top to bottom, wherein: The physical layer includes a physical model module, a data acquisition module, and a data processing module; Communication layer, including data transmission module and data storage module; Virtual layer, including digital twin model module; The application layer includes the instruction editing module and the software tool module.
[0028] Specifically, the physical model module includes: A complex device physical entity is a mechanical device formed by assembling various actuators that perform specific functions of the complex device, and is a physical entity formed by assembling electronic devices required to achieve specific functions of the complex device on the basis of the mechanical device. The various actuators that perform specific functions of the complex device are composed of specific components; The physical environment required by the physical entity of a complex device to realize its function, wherein the physical environment is the physical space in which the physical entity of the complex device realizes its function and the sum of the physical quantities in the space that can affect the operation process of the physical entity of the complex device.
[0029] Specifically, the data acquisition module includes: The device sensor group and environmental sensor group required to collect multi-source real-time data; The device sensor group is used to collect physical quantities of the operation process of the complex device physical entity, including displacement, velocity, acceleration, voltage, current, pressure, and flow; The environmental sensor group is used to collect physical quantities of the physical environment during the operation of the physical entity of the complex equipment, and the physical quantities of the physical environment include temperature, humidity, pressure, light, and gas content.
[0030] Specifically, the data processing module is preset with an algorithm for filtering, classifying, integrating and detecting anomalies of multi-source real-time data.
[0031] It should be noted here that the multi-source real-time data is the data generated during the operation of the physical model module.
[0032] Specifically, the data transmission module includes a data exchange unit, a data transmission protocol unit, an industrial network data transmission protocol unit and a data transmission interface unit, wherein: The data exchange unit includes a receiving data thread for the host computer to receive multi-source real-time data, and a sending data thread for the host computer to send an instruction set to the physical model module; The data transmission protocol unit includes a data transmission protocol used for data exchange between the host computer and the main host, and the data transmission protocol unit includes 5G and TCP; The industrial network data transmission protocol unit includes a data transmission protocol for the physical model module to transmit multi-source real-time data to the host computer and for the physical model module to receive the host computer instruction set, and the data transmission protocol includes CAN and SPI; The data transmission interface unit is used for data transmission between the host computer and the main host, and the data transmission mode includes RS-485, RS-232, and USB.
[0033] Specifically, the data storage module includes: Database interface unit and real-time data database; The database interface unit includes an interactive channel between the system framework and the real-time data database established based on database link technology; The real-time data database is a hierarchical database developed based on MySQL, SQLSERVER or ORACLE database and stores administrator information, multi-source real-time data, exception handling records, operation logs and exception handling methods.
[0034] Specifically, the digital twin model module includes a digital twin model, and the digital twin model includes: The geometry model, also called Geometry_Model, includes the 3D model of the complex equipment, the manufacturing information of the complex equipment, the 3D model update algorithm of the complex equipment, and the distribution information of the sensors and controllers of the complex equipment; Simulation models related to complex equipment, also called Activity_Model, include the mechanism dynamics simulation model, mechanism kinematics simulation model, hydraulic system simulation model, electrical system simulation model, equipment operation status simulation model and finite element simulation model of complex equipment; The equipment maintenance model, also known as Maintain_Model, includes multi-source real-time data, a multidisciplinary analysis model based on complex equipment, a fault diagnosis method based on complex equipment, and an abnormality handling method based on complex equipment.
[0035] Specifically, the instruction editing layer includes: An instruction editor unit and an instruction set unit, wherein the instruction editor unit includes a device manager and a digital twin system; The digital twin system is used to handle complex equipment anomalies; The device manager is used to perform device operations on complex devices; The instruction set unit includes an exception handling instruction set and a device operation instruction set. The device administrator is used to edit the device operation instruction set, and the digital twin system is used to edit the exception handling instruction set.
[0036] It should be noted here that the complex device includes a controller, which is connected to the complex device control system and is used to control the working state of the complex device through instructions.
[0037] It should be noted here that after the physical entity of the complex device generates an exception, the digital twin system will judge the type of exception and the location where the exception occurred. After the type of exception and the location where the exception occurred are judged, the instruction editing stage is entered; the digital twin system will edit the exception handling instruction set according to the type and location of the exception, and the exception handling instruction set is transmitted to the controller of the complex device through the data transmission and storage layer. The controller executes the exception handling instruction set, thereby completing the operations specified by the exception handling instruction set content, and feedbacks the execution results of the exception handling instruction set.
[0038] It should be noted here that the application layer also includes a device administrator layer, and the device administrator layer includes a device maintenance administrator, a device operation administrator, and a device monitoring administrator.
[0039] Specifically, the software tool module includes: Software tools for building databases, including MySQL or SQLSERVER or ORACLE; Software tools for building virtual 2D and 3D models, including Solid-works and CAD; Software tools for building simulation models, including AMESim, ADAMS, and ANSYS; Software tools used to implement algorithms, including JAVA and Python.
[0040] Specifically, the application layer is used to implement the functions of the digital twin system, including digital twin model update, fault analysis, exception handling, real-time status monitoring, and equipment operation.
[0041] Specifically, the real-time data database stores device administrator information, multi-source real-time data, exception handling records, operation logs, and exception handling methods; The exception handling record includes the time when the exception occurred, the location where the exception occurred, and the exception handling method; The operation log includes the equipment operation time, equipment operation content, and equipment operator; The exception handling method includes the original exception handling method and the newly added exception handling method under the action of the algorithm; The original exception handling method is the exception handling method that already exists in the database before the system database of the present invention adds the first new exception handling method under the algorithm; The newly added exception handling method under the action of the algorithm is that when an exception is detected in the equipment and the cause of the exception is analyzed through a fault diagnosis method based on complex equipment, the cause of the exception is updated by the exception handling method based on complex equipment to form a new exception handling method. The cause of the exception does not exist in the original database but is a new exception handling method newly stored in the database.
[0042] It should be noted here that the data transmission process of the digital twin system architecture applied to complex equipment described in the present invention is illustrated below by way of example: like Figure 2 As shown, the data transmission process involves a host computer, a microcontroller-sensor, a microcontroller-controller, a physical model of a complex device, a database, a main host, and the data transmission part in the data transmission and storage layer connecting the above components (RS-485TX, RS485RX in the figure), the industrial network data transmission protocol part (CAN_TX, CAN_RX in the figure), the database interface part (JDBC in the figure), SENSOR_1, SENSOR_2, ..., SENSOR_N, CONTROL_1, CONTROL_2, ..., CONTROL_N, ADC_1, ADC_2, ..., ADC_N, IO1, IO2, ..., ION, 5G / TCP.
[0043] Among them, the data transmission part in the data transmission and storage layer (RS-485TX, RS485RX in the figure) is used to connect the host computer and the microcontroller-sensor; the industrial network data transmission protocol part (CAN_TX, CAN_RX in the figure) is used to connect the microcontroller-sensor and the microcontroller-controller; SENSOR_1, SENSOR_2, ..., SENSOR_N, CONTROL_1, CONTROL_2, ..., CONTROL_N is used to connect the microcontroller-sensor, the microcontroller-controller and the physical model of the complex equipment; the database interface part (JDBC in the figure) is used to connect the host computer and the database; ADC_1, ADC_2, ..., ADC_N, IO1, IO2, ..., ION are used to connect SENSOR_1, SENSOR_2, ..., SENSOR_N, CONTROL_1, CONTROL_2, ..., CONTROL_N, microcontroller-sensor, microcontroller-controller; 5G / TCP is used to connect the host computer and the main host.
[0044] When the host computer receives real-time data from multiple sources, the data transmission process is: complex device physical model - SENSOR_X (X=1,2,3,...,N) - ADC_X (X=1,2,3,...,N) - microcontroller-sensor - data transmission and data transmission part in the storage layer (RS-485TX, RS485RX in the figure) - host computer - database interface part (JDBC in the figure) - database.
[0045] When the device administrator sends an instruction set from the host computer to the physical model of the complex device, the data transmission process is: host computer - data transmission and data transmission part in the storage layer (RS-485TX, RS485RX in the figure) - microcontroller - sensor - industrial network data transmission protocol part (CAN_TX, CAN_RX in the figure) - microcontroller - controller - IOX (X=1,2,3,......,N) - CONTROL_X (X=1,2,3,......,N).
[0046] When transmitting data to the main host, the data transmission process is: host computer - 5G / TCP - host computer. This data transmission path is used for data transmission between multiple complex devices and the main host.
[0047] It should be noted here that the present invention also proposes a model updating method for a digital twin model of a complex device. The model updating method for a digital twin model of a complex device in the present invention is described below: See also Figure 4 , complex device twin model updates as follows: The data acquisition module includes an equipment sensor group and an environmental sensor group. The equipment sensor group collects physical quantities generated during the operation of the physical entity of complex equipment, including displacement, velocity, acceleration, voltage, current, pressure, and flow; the environmental sensor group collects physical quantities in the operating environment of complex equipment, including temperature, pressure, light, and humidity.
[0048] It can be understood that the above-mentioned physical quantities are multi-source real-time data.
[0049] After the sensor part in the data acquisition and processing layer collects multi-source real-time data, the multi-source real-time data is processed by the data processing part of the data acquisition and processing layer, that is, filtering, classification, integration and anomaly detection to form processed multi-source real-time data.
[0050] The processed multi-source real-time data is transmitted to the host computer through the RS-485 interface of the data transmission and storage layer data transmission interface part and the receiving data thread in the data exchange part. The host computer obtains the database link through the database interface part of the data transmission and storage layer, establishes the connection between this system and the database, and stores the processed multi-source real-time data in the database.
[0051] While the above steps are being performed, multi-source real-time data passes through the complex equipment 3D model update algorithm of the digital twin model layer Geometry_Model, causing the Geometry_Model complex equipment 3D model to perform the model update operation, thereby updating the complex equipment 3D model in real time.
[0052] Complex equipment 3D model update algorithm: Among them, new_distance_data is the displacement data in multi-source real-time data; real_distance_data is the displacement data in the twin model; △data_distance is the displacement deviation; new_angle_data is the rotation angle data in multi-source real-time data; real_angle_data is the rotation angle data in the twin model; △data_angle is the angle deviation; Multi_source Real_Time Data refers to multi-source real-time data; DISTANCES, ANGLES refers to the type of multi-source real-time data to be obtained, which refers to the displacement and rotation angle in the multi-source real-time data. For different complex devices, there can be different types of representations such as this; ComplexDevice.mechanism.component is to obtain the component of a certain actuator of a complex device in the virtual space; UseTransform() is a model transformation method used to synchronize the actions of the complex equipment 3D model and the physical entity of the digital twin model; Transformation types, TRANSFORM_TYPE_MOVE and TRANSFORM_TYPE_ROTATE, correspond to component movement and rotation. Different complex devices can have different representations of this type. getModelData() is a method for obtaining data in the twin model; Compensation_Distances() and Compensation_Angles() are methods for compensating displacement and rotation angles; Device.flush() refreshes the 3D model of complex devices and displays their real-time status; Distance_Allowable_Error, Angle_Allowable_Error are the allowable errors of displacement and angle. For different complex equipment, there may be different types of representations such as this; See also Figure 5 , the exception handling process of the present invention is as follows: Multi-source real-time data is used for anomaly detection in the data collection and processing layer of the host computer. Anomaly detection process: Among them, Multi_source real_time Data is multi-source real-time data; THRESHOULD is the set threshold. When the multi-source real-time data value exceeds the threshold, it is considered abnormal. The judgment condition is as shown in the figure "Multi_source real_time Data>=THRESHOULD?"; abnormal_sign abnormal detection flag, which is a binary variable. "1" means an abnormality occurs and needs to be processed, and "0" means no abnormality. abnormal_type is the abnormal type variable; getAbnormalType(Multi_source real_time Data) method to get the abnormal type; If there is no exception, it returns NULLABNORMAL, indicating that the complex device is operating normally. When abnormal_sign = 1 and abnormal_type != null, the digital twin model Maintain_Model retrieves the exception handling method from the database according to abnormal_type and selects the best exception handling method in Maintain_Model; After the optimal exception handling solution is selected, the digital twin system in the instruction editing layer edits the exception handling instruction set in the host computer according to the optimal exception handling solution. The exception handling instruction set is sent to the data exchange part of the data transmission and storage layer through the RS-485 interface part of the data transmission and storage layer. Figure 2 The microcontroller-sensor generates an operation log and stores it in a multi-source real-time data database, which is then sent to the CAN industrial network data transmission protocol through the data transmission and storage layer. Figure 2 Microcontroller - controller.
[0053] Figure 2 Microcontroller-controller control Figure 2 The controllers CONTROL_1, CONTROL_2, CONTROL_3, ..., CONTROL_N in the middle, then operate the physical entity of the complex equipment to perform exception processing, and then feedback the operating status of the complex equipment after the execution of the instruction set through the sensor part of the data acquisition and processing layer. According to the abnormality detection, the above steps are repeated until there is no abnormality in the equipment, and the exception processing link is completed.
[0054] See also Figure 6 , the fault analysis process of the present invention is as follows: The host computer reads the exception information and exception handling records from the real-time data database of the data transmission and storage layer. Reading the exception handling records will generate the exception handling method and processing results as shown in the figure. The exception information is input into the digital twin model layer Maintain_Model based on the multidisciplinary analysis model of complex equipment and the fault diagnosis method based on complex equipment; Multidisciplinary analysis model based on complex equipment and fault diagnosis method based on complex equipment: Among them, result_x (x=1,2,3,......) is the analysis result of a subject in the model; final_result is the final result after comprehensive multidisciplinary analysis, which determines the cause of the failure; Unite_Analysis(result_1,result_2,result_3,result_4,......) is the subjects involved; The results of the analysis are combined into a method of comprehensive analysis, namely, a fault diagnosis method based on complex equipment.
[0055] Based on final_result, the location and cause of the complex equipment fault are obtained, and the location and cause of the fault are displayed on the three-dimensional model of the complex equipment in the digital twin model and fed back to the equipment administrator layer to perform maintenance and repair operations on the complex equipment.
[0056] After finding the cause of the fault, combined with the exception handling method and processing results, the exception handling method based on complex equipment is updated. The update algorithm is as follows: Update algorithm based on abnormal handling method of complex equipment: Among them, Disposition_Method is the fusion data obtained by merging the fault cause malfunction_reasons, the exception handling method and the processing result error_disposition_mode_and_result using the merge() method, that is, the new exception handling method Disposition_Method; old_disposition_Method is the exception handling method that already exists in the database and is obtained from the database through the getOldMethodFromDatabase() method; After getting the Disposition_Method, exception handling method and result, determine whether the new exception handling method Disposition_Method exists in the database. Use the method exist(Disposition_Method). This method is a method with a return value. If the new exception handling method does not exist in the database, it returns "0", otherwise it returns "1". If exist(Disposition_Method) returns "1", use Disposition_Method.compare(old_Disposition_Method) to compare the existing exception handling method with the new one. This method is a function with a return value, and its return value is "1" or "0". When the new exception handling method is better than the existing one, it returns "1", otherwise it returns "0"; If "1" is returned after the judgment, the method replace(old_Disposition_Method) is used to replace the exception handling method that already exists in the original database. Otherwise, ignore(Disposition_Method) is used to abandon the new exception handling method; If exist(Disposition_Method) returns "0", use the method addNewErrorDispositionMethod(Disposition_Method) to store the new exception handling method in the database; See also Figure 7 , the process of operating the device of the present invention is as follows: The operation administrator at the equipment administrator layer performs the operation, and the equipment administrator (operation administrator) at the instruction editing layer edits the operation instruction set to generate the equipment operation instruction set. The equipment parameters that change due to the operation instruction set are extracted from the equipment operation instruction set and input into the relevant simulation models of the Activity_Model at the digital twin model layer, such as the complex equipment mechanism dynamics simulation model, complex equipment mechanism kinematics simulation model, complex equipment hydraulic system model, and complex equipment finite element model, etc.; After inputting the relevant models of Activity_Model in the digital twin model layer, run the simulation, display the simulation results on the complex equipment 3D model, and feed back to the equipment operation administrator in the equipment administrator layer. The equipment operation administrator modifies the equipment operation instruction set according to the simulation results and the actions of the complex equipment 3D model to determine whether the equipment operation requirements are met until the best equipment operation instruction set is obtained; After the above steps are completed, under the action of the sending data thread in the data exchange part of the data transmission and storage layer, the device operation instruction set is transmitted to the data transmission and storage layer through the data transmission and storage layer data transmission interface. Figure 2 In the microcontroller-sensor, the operating device operation instruction set is then transmitted to the microcontroller-controller through the CAN industrial network transmission protocol, thereby completing the device operation; It should be noted that the implementation of the real-time status monitoring described in the present invention is as follows: The results of the complex equipment three-dimensional model of the twin model layer Geometry_Model after complex equipment twin model update and multi-source real-time data anomaly detection are displayed on the host computer; at the same time, the multi-source real-time data is displayed on the host computer in the form of real-time curves, thereby realizing real-time status monitoring.
[0057] The above algorithm description only represents the implementation process of the algorithm and does not represent any programming language. When the algorithm is implemented later, a suitable programming language can be selected to write the algorithm.
[0058] It can be understood that the digital twin system architecture proposed in the present invention is applied to complex equipment, and the system architecture includes an application layer, a virtual layer, a communication layer and a physical layer that transmit data from top to bottom through Ethernet, wherein: the physical layer includes a physical model module, a data acquisition module and a data processing module; the communication layer includes a data transmission module and a data storage module; the virtual layer includes a digital twin model module; the application layer includes an instruction editing module and a software tool module. The physical model module provides multi-source real-time data of complex equipment. The data acquisition module and the data processing module collect and process the multi-source real-time data generated by the physical model layer in real time. The processed multi-source real-time data is transmitted to the host computer through the data transmission module and the data processing module, and the functions of storing multi-source real-time data in the real-time data database, updating the digital twin model, fault analysis, exception handling, real-time status monitoring and equipment operation are completed in the host computer. The various data required by the digital twin model layer come from the multi-source real-time data processed by the data acquisition module and the data processing module. The above data will be used for the digital twin model layer to update the real-time three-dimensional model of complex equipment; simulation, fault analysis, exception handling and real-time status monitoring of models such as mechanism dynamics, mechanism kinematics, hydraulic system, operation process, finite element, etc. The equipment administrator layer includes equipment operation administrators, who operate equipment according to the twin results of the twin model layer; equipment maintenance administrators, who are used for equipment maintenance and repair; equipment monitoring administrators, who are used to monitor system dynamics on the host computer. The instruction editing layer is used for equipment administrators or digital twin systems to edit instruction sets. The edited instruction sets are sent to the controller of complex equipment through the data transmission and storage layer, and then exception handling or operation of complex equipment is completed. At the same time, an operation log corresponding to the instruction set operation is generated, and the operation log is stored in the database through the data transmission module and the data storage module. The software tool layer contains the tools required for constructing a digital twin system architecture for complex equipment described in the present invention, such as MySQL, JAVA, AMESim, ANSYS, etc. The application layer described in the present invention is a series of functions that can be realized by the system.
[0059] Therefore, the digital twin system architecture applied to complex equipment described in the present invention proposes a common architecture of the digital twin system, which can realize the association and coordination between different levels based on this common architecture, and then complete the design of the digital twin system, and realize the digital twin model update, fault analysis, exception handling, real-time status monitoring, equipment operation and other functions of complex equipment.
[0060] In a digital twin system architecture applied to complex equipment proposed by the present invention, the multi-source real-time data generated by the physical model layer is collected and processed through the data acquisition and processing layer, and the data is stored in the database through the data transmission and storage layer, and the multi-source real-time data after data processing is transmitted to the host computer, and the multi-source real-time data is stored in the host computer database, the digital twin model is updated, fault analysis, exception handling, real-time status monitoring and equipment operation are completed in the host computer. The exception handling instruction set or the equipment operation instruction set edited by the device administrator or the digital twin system in the instruction editing layer is used to perform corresponding processing on the exceptions generated during the operation of the complex equipment or operate the operation of the complex equipment. The solution of establishing a digital twin model for the physical entity of the complex equipment solves the problems of packet loss, packet splitting and packet error that always exist during data transmission, and realizes the accurate perception of complex equipment sensors, efficient transmission of multi-source real-time data, real-time update of digital twin models, accurate equipment fault diagnosis, rapid equipment exception handling and rapid and accurate response of equipment behavior control.
[0061] The various technical features described above can be combined arbitrarily. Although all possible combinations of these technical features are not described, any combination of these technical features should be considered to be covered by this specification as long as there is no contradiction in such combination.
[0062] The specific implementation of the present invention described above does not constitute a limitation on the protection scope of the present invention. Any other corresponding changes and modifications made based on the technical concept of the present invention should be included in the protection scope of the claims of the present invention.
Claims
1. A digital twin system architecture applied to complex equipment, characterized in that: The system architecture includes an application layer, a virtual layer, a communication layer and a physical layer for transmitting data through Ethernet from top to bottom, wherein: The physical layer includes a physical model module, a data acquisition module, and a data processing module; Communication layer, including data transmission module and data storage module; Virtual layer, including digital twin model module; The application layer includes the instruction editing module and the software tool module.
2. The digital twin system architecture for complex equipment according to claim 1, characterized in that: The physical model module comprises: A complex device physical entity is a mechanical device formed by assembling various actuators that perform specific functions of the complex device, and is a physical entity formed by assembling electronic devices required to achieve specific functions of the complex device on the basis of the mechanical device. The various actuators that perform specific functions of the complex device are composed of specific components; The physical environment required by the physical entity of a complex device to realize its function, wherein the physical environment is the physical space in which the physical entity of the complex device realizes its function and the sum of the physical quantities in the space that can affect the operation process of the physical entity of the complex device.
3. The digital twin system architecture for complex equipment according to claim 1, characterized in that: The data acquisition module comprises: The device sensor group and environmental sensor group required to collect multi-source real-time data; The device sensor group is used to collect physical quantities of the operation process of the complex device physical entity, including displacement, velocity, acceleration, voltage, current, pressure, and flow; The environmental sensor group is used to collect physical quantities of the physical environment during the operation of the physical entity of the complex equipment, and the physical quantities of the physical environment include temperature, humidity, pressure, light, and gas content.
4. The digital twin system architecture for complex equipment according to claim 3 is characterized in that: The data processing module is preset with algorithms for filtering, classifying, integrating and detecting anomalies of multi-source real-time data.
5. The digital twin system architecture for complex equipment according to claim 3, characterized in that: The data transmission module includes a data exchange unit, a data transmission protocol unit, an industrial network data transmission protocol unit and a data transmission interface unit, wherein: The data exchange unit includes a receiving data thread for the host computer to receive multi-source real-time data, and a sending data thread for the host computer to send an instruction set to the physical model module; The data transmission protocol unit includes a data transmission protocol used for data exchange between the host computer and the main host, and the data transmission protocol unit includes 5G and TCP; The industrial network data transmission protocol unit includes a data transmission protocol for the physical model module to transmit multi-source real-time data to the host computer and for the physical model module to receive the host computer instruction set, and the data transmission protocol includes CAN and SPI; The data transmission interface unit is used for data transmission between the host computer and the main host, and the data transmission mode includes RS-485, RS-232, and USB.
6. The digital twin system architecture for complex equipment according to claim 1, characterized in that: The data storage module comprises: Database interface unit and real-time data database; The database interface unit includes an interactive channel between the system framework and the real-time data database established based on database link technology; The real-time data database is a hierarchical database developed based on MySQL, SQLSERVER or ORACLE database and stores administrator information, multi-source real-time data, exception handling records, operation logs and exception handling methods.
7. The digital twin system architecture for complex equipment according to claim 6, characterized in that: The digital twin model module includes a digital twin model, and the digital twin model includes: Geometric model, including the 3D model of complex equipment, manufacturing information of complex equipment, 3D model update algorithm of complex equipment, and distribution information of sensors and controllers of complex equipment; Simulation models related to complex equipment, including mechanism dynamics simulation model, mechanism kinematics simulation model, hydraulic system simulation model, electrical system simulation model, equipment operation status simulation model and finite element simulation model of complex equipment; Equipment maintenance model, including multi-source real-time data, multidisciplinary analysis model based on complex equipment, fault diagnosis method based on complex equipment, and abnormality handling method based on complex equipment.
8. The digital twin system architecture for complex equipment according to claim 1, characterized in that: The instruction editing layer includes: An instruction editor unit and an instruction set unit, wherein the instruction editor unit includes a device manager and a digital twin system; The digital twin system is used to handle complex equipment anomalies; The device manager is used to perform device operations on complex devices; The instruction set unit includes an exception handling instruction set and a device operation instruction set. The device administrator is used to edit the device operation instruction set, and the digital twin system is used to edit the exception handling instruction set.
9. The digital twin system architecture for complex equipment according to claim 1, characterized in that: The software tool module includes: Software tools for building databases, including MySQL or SQLSERVER or ORACLE; Software tools for building virtual 2D and 3D models, including Solid-works and CAD; Software tools for building simulation models, including AMESim, ADAMS, and ANSYS; Software tools used to implement algorithms, including JAVA and Python.
10. The digital twin system architecture for complex equipment according to claim 7, characterized in that: The application layer is used to implement the functions of the digital twin system, including digital twin model update, fault analysis, exception handling, real-time status monitoring, and equipment operation.
11. The digital twin system architecture for complex equipment according to claim 7, characterized in that: The real-time data database stores device administrator information, multi-source real-time data, exception handling records, operation logs, and exception handling methods; The exception handling record includes the time when the exception occurred, the location where the exception occurred, and the exception handling method; The operation log includes the equipment operation time, equipment operation content, and equipment operator; The exception handling method includes the original exception handling method and the newly added exception handling method under the action of the algorithm; The original exception handling method is the exception handling method that already exists in the database before the system database of the present invention adds the first new exception handling method under the algorithm; The newly added exception handling method under the action of the algorithm is that when an exception is detected in the equipment and the cause of the exception is analyzed through a fault diagnosis method based on complex equipment, the cause of the exception is updated by the exception handling method based on complex equipment to form a new exception handling method. The cause of the exception does not exist in the original database but is a new exception handling method newly stored in the database.