Production line design simulation system and simulation method using digital twinning technology

Abstract

The invention relates to the field of production line design, in particular to a production line design simulation system utilizing a digital twinning technology, which comprises an industrial modeling unit, a logistics simulation unit and a digital twinning unit. The industrial modeling unit establishes a logistics model and a trafficability model based on production line design inputs. And the logistics simulation unit calculates and obtains logistics process data by utilizing a logistics model according to the initial logistics parameters. And the digital twin unit establishes a simulation production line according to the trafficability model, then receives logistics process data, and displays the logistics state on the simulation production line in a simulation animation form. And the designer generates a new logistics parameter according to the logistics state, and performs a new round of iteration until the design requirement is met. The invention further comprises a simulation method. According to the invention, trafficability simulation and logistics simulation of the production line are combined together through the digital twin unit to cooperatively complete the simulation process. According to the method, the field process can be restored more truly, the performance overhead cost is reduced, and the simulation efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the field of production line design, and in particular to a production line design simulation system and a simulation method using digital twin technology. Background Art

[0002] In the development of automobile products, it is necessary to design and simulate the production line and production capacity of the automobile. The most commonly used ones are logistics simulation and passability simulation test to ensure that the designed production line can meet the design requirements, produce the designed model and reach the target production capacity. The general steps include:

[0003] Both the production line passability and logistics need to be simulated, so in the design, accurate modeling needs to be performed on their respective professional software. After the model is completed, it is necessary to program and develop various operating conditions and results, and implement specific simulation program logic based on the model. Then, according to the design requirements of the production line, enter the relevant parameters of the simulation. Finally, the production line passability simulation and logistics simulation are simulated separately, and each generally requires multiple simulations. Finally, combine the production line passability simulation and logistics simulation to determine whether the production line design meets the standards. If the simulation result is not achieved, it is necessary to find the cause, adjust the parameters, and repeat the process.

[0004] The main drawbacks of the above method are:

[0005] 1. Logistics simulation is only designed and simulated under general conditions. Due to the software platform, logistics simulation and production line passability simulation are separated and independently simulated, so some physical limitations in the real environment, such as traffic congestion, cannot be simulated.

[0006] 2. Production line design simulation mainly focuses on model simulation, and does not have animation, collision and other logical functions. At the same time, the verification process is very slow due to performance reasons, and it is impossible to perform flexible, fast, and large-scale simulation verification.

[0007] 3. The overall simulation effect is relatively simple, and the effect on corporate publicity is not ideal. We hope to have a simulation process that is close to the real effect.

[0008] 4. The relevant simulation and animation production software is relatively professional and has a high learning cost. Summary of the invention

[0009] The purpose of the present invention is to provide a production line design simulation system and simulation method using digital twin technology, mainly to solve the problems existing in the above-mentioned prior art.

[0010] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is to provide a production line design simulation system using digital twin technology, characterized in that it includes an industrial modeling unit, a logistics simulation unit and a digital twin unit;

[0011] The industrial modeling unit establishes a logistics model and a passability model based on the production line design input, and then sends the logistics model to the logistics simulation unit, and sends the passability model to the digital twin unit;

[0012] The logistics simulation unit calculates logistics process data based on the initial logistics parameters and using the logistics model, and sends the logistics process data to the digital twin unit;

[0013] The digital twin unit establishes a simulated production line based on the passability model, then receives the logistics process data, and displays the logistics status on the simulated production line in the form of a simulation animation; the designer generates new logistics parameters based on the logistics status and delivers them to the logistics simulation unit for a new round of iteration until the logistics status meets the design requirements.

[0014] Furthermore, the industrial modeling unit includes a logistics modeling module and a passability modeling module;

[0015] The logistics modeling module generates the logistics model based on the production line design input, which includes the logistics scheduling information in the production line; the passability modeling module generates the passability model based on the production line design input, which includes the action information of each equipment and material on the production line.

[0016] Furthermore, the logistics simulation unit includes a model import module, a parameter input module and a process simulation module;

[0017] The model import module initializes the process simulation module based on the logistics model, so that subsequent simulations are all based on the input logistics model; the parameter input module reads the logistics parameters and configures them into the process simulation module; the process simulation module calculates the logistics process data based on the logistics model and the logistics parameters.

[0018] Further, the digital twin unit includes a layout generation module, a simulation conversion module, a data driving module and an animation output module;

[0019] The layout generation module reads the passability model, and generates simulation equipment on the digital twin production line based on the passability model; the simulation conversion module reads the logistics process data, performs data processing based on the logistics process data, generates action data for driving the simulation equipment, and sends it to the data driving module; the data driving module generates animation data corresponding to each of the simulation equipment based on the action data; the animation output module generates and displays the simulation animation reflecting the real-time status of each simulation equipment based on the animation data.

[0020] Furthermore, the digital twin unit also includes a statistical output module; the statistical output module extracts video from the simulation animation and saves it for later retrieval.

[0021] Furthermore, the simulation device includes a simulation conveyor belt and a simulation robot.

[0022] Furthermore, the data processing of the simulation conversion module includes data interpolation.

[0023] The present invention also discloses a simulation method using the production line design simulation system using the digital twin technology, which is characterized by comprising the steps of:

[0024] Step S10, establishing the logistics model and the trafficability model respectively using the industrial modeling unit according to the production line design input;

[0025] Step S11, importing the passability model into the digital twin unit;

[0026] Step S12, importing the logistics model into the logistics simulation unit;

[0027] Step S13, using a logistics simulation unit to read logistics parameters and generate the logistics process data based on the logistics model;

[0028] Step S14, importing the logistics process data into the digital twin unit;

[0029] Step S15, the digital twin unit generates and displays a simulation animation in combination with the passability model and the logistics process data;

[0030] Step S16, the designer obtains the logistics status according to the simulation animation;

[0031] Step S17, the designer evaluates whether the logistics status meets the standard; if it meets the standard, go to step S18, otherwise after adjusting the logistics parameters, jump to step S13;

[0032] Step S18, completing the production line design according to the logistics model, the passability model and the logistics parameters.

[0033] Furthermore, it is characterized in that step S15 includes sub-steps:

[0034] Step S151, the simulation conversion module in the digital twin unit reads the logistics process data and converts it into animation input parameters;

[0035] Step S152, the simulation conversion module performs data interpolation based on the animation input parameters, supplements the information required by the simulation device, and generates action data for each corresponding simulation device;

[0036] Step S153, the data driving module in the digital twin unit reads the action data and generates animation data for each of the simulation devices;

[0037] Step S154: the animation output module in the digital twin unit generates and displays the simulation animation according to the animation data.

[0038] Furthermore, a method for designing a production line based on historical simulation data is also included, comprising the steps of:

[0039] Step S20, using the statistical output module in the digital twin unit to read the videos saved from the previous simulation animations;

[0040] Step S21, extracting the logistics status corresponding to the video;

[0041] Step S22, performing statistical analysis on the logistics status to select the optimal logistics parameters;

[0042] Step S23, completing the production line design according to the logistics model, the passability model and the logistics parameters.

[0043] In view of the above technical features, the present invention utilizes the production line design simulation system and simulation method of digital twin technology, with the help of the digital twin platform system, through a refined model, combined with the process data generated by the logistics simulation and the digital twin production line drive data, to check whether the vehicle interferes with or collides with the production line during the production process. At the same time, based on the logistics simulation data, the logistics equipment in the workshop is guided to execute the logistics process according to the simulation parameters to verify the logistics efficiency and ensure that it will not interfere with or collide with other equipment. Compared with the prior art, the present invention has the following advantages:

[0044] 1. The present invention combines the throughput simulation and logistics simulation of the production line through the digital twin unit to collaboratively complete the simulation process. In this way, during the simulation process, the two can refer to each other's real data as comprehensive parameter verification.

[0045] 2. The physical engine of the digital twin unit in the present invention can more realistically restore the on-site process. Since the scene is consistent with the simulation data, the simulation result is very close to the final real production line and has certain reference value.

[0046] 3. The digital twin unit in the present invention has exquisite pictures, and the optimized model not only ensures accurate and detailed restoration, but also reduces performance overhead and improves simulation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a system block diagram of a preferred embodiment of the production line design simulation system using digital twin technology of the present invention;

[0048] Figure 2 It is a schematic diagram of information transmission of a preferred embodiment of a production line design simulation system using digital twin technology of the present invention;

[0049] Figure 3 It is a method flow chart of a preferred embodiment of a simulation method of a production line design simulation system using digital twin technology of the present invention;

[0050] Figure 4 It is a flow chart of a method for designing a production line using historical simulation data in a preferred embodiment of the simulation method of the production line design simulation system using digital twin technology of the present invention.

[0051] In the figure: 100-industrial modeling unit, 200-logistics simulation unit, 300-digital twin unit;

[0052] 101-Logistics modeling module, 102-Passability modeling module;

[0053] 201-model import module, 202-parameter input module, 203-process simulation module;

[0054] 301 - layout generation module, 302 - simulation conversion module, 303 - data driving module, 304 - animation output module, 305 - statistics output module. DETAILED DESCRIPTION

[0055] The present invention will be further described below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms fall within the scope limited by the appended claims of the application equally.

[0056] See also Figure 1 and Figure 2 The present invention discloses a production line design simulation system using digital twin technology. As shown in the figure, a preferred embodiment thereof is composed of an industrial modeling unit 100, a logistics simulation unit 200 and a digital twin unit 300.

[0057] In the production line design, the industrial modeling unit 100 is used to establish a logistics model and a passability model according to the production line design input. The logistics model describes the flow mode of each material in the production line and contains all the logistics scheduling information in the production line. The passability model mainly describes the characteristics of the production line, such as the setting of the workstation, the layout of the site, and the action information of each equipment and material. Using the passability model and the logistics model, the designer can check whether there is a logistics conflict in the production line, or optimize the production line layout or logistics planning. The logistics model is sent to the logistics simulation unit 200 as input. The logistics simulation unit 200 calculates the logistics process data based on the initial logistics parameters based on the logistics model. The passability model is sent to the digital twin unit 300 as input. The digital twin unit 300 establishes a simulated production line based on the passability model, and then combines the logistics process data to simulate the logistics status on the simulated production line, which is generally displayed to the designer in the form of animation. According to the logistics status, the designer can adjust the parameters input to the logistics simulation unit 200 to enter the next round of iteration until the logistics status on the simulated production line meets the design requirements.

[0058] The industrial modeling unit 100 includes a logistics modeling module 101 and a passability modeling module 102, which are used to establish a logistics model and a passability model, respectively. The industrial modeling unit 100 is mainly used to accurately construct the model, and its accuracy is mainly reflected in the ability to accurately reflect the outline and functional details of the object. In particular, for infrastructure such as building layout, walls, roads, etc., the simulation software can ensure a high degree of consistency with the actual situation. In the scene, the appearance size of the equipment is consistent with the real equipment, even down to the details of each part. The input of the logistics modeling module 101 is the production line design input provided by the designer, and the output is the logistics model. The input of the passability modeling module 102 is also the production line design input provided by the designer, and its output is the passability model.

[0059] The logistics simulation unit 200 includes a model import module 201, a parameter input module 202 and a process simulation module 203. The logistics simulation unit 200 has the function of importing industrial simulation software scenes or models, and can also construct models that represent equipment or production lines with simple geometric bodies. The core is to realize parametric simulation of the constructed scenes through rapid configuration and programming to reproduce the production or logistics process and to perform statistics on relevant data. Subsequently, the simulation results are analyzed using statistical methods to draw scientific conclusions. In the logistics simulation unit 200, the logistics model as input determines the specific process of the simulation, and the logistics parameters affect the specific calculation factors when the specific process of the simulation remains unchanged. The model import module 201 is responsible for reading the logistics model and initializing the simulation process in the process simulation module 203 according to the logistics model, that is, the subsequent simulations are based on the read logistics model. Before each logistics simulation, the model import only needs to be executed once, and the logistics parameters only need to be adjusted later. Similarly, the parameter input module 202 is responsible for reading the logistics parameters and configuring them in the process simulation module 203. It is used to adjust the various input parameters of the process simulation module 203 in the simulation calculation. In the simulation of a round of production line design, the logistics parameters will be adjusted many times, so the parameter input module 202 needs to read the latest logistics parameters each time and configure them in the process simulation module 203 to guide its simulation calculation each time. The process simulation module 203 is the module that actually completes the simulation calculation. It calculates the logistics process data based on the current logistics model and logistics parameters according to the simulation process specified by the logistics model and the parameters specified by the logistics parameters, and outputs the logistics process data to the digital twin unit.

[0060] The digital twin unit 300 includes a layout generation module 301, a simulation conversion module 302, a data drive module 303, an animation output module 304, and a statistical output module 305. The digital twin unit 300 provides a set of standardized operating functions, the content displayed is consistent with the actual on-site environment, and provides data management, model management and other functions, which can use the real data provided on site to drive the animation display platform. The layout generation module 301 is responsible for reading the passability model as input, and then initializing the digital twin production line based on the passability model, such as generating simulation equipment on the digital twin production line, setting the layout of the simulation equipment, and defining the behavior of the simulation equipment. The simulation equipment includes a simulation conveyor belt and a simulation robot. In the simulation of a round of production line design, the initialization of the digital twin production line only needs to be performed once, and the subsequent work is to display the working status of the digital twin production line to the designer under the drive of the logistics process data.

[0061] The simulation conversion module 302 is responsible for reading the logistics process data, and then processing the data based on the logistics process data to generate the status data of the digital twin production line, that is, generating the action data used to drive each simulation device on the digital twin production line, and then sending it to the data driving module 303. During the data processing process, the simulation conversion module 302 will also perform data interpolation to fill the difference between the change rate of the logistics process data and the refresh rate of the digital twin production line. In a round of production line design simulation, the simulation conversion module 302 will read the logistics process data multiple times, thereby continuously outputting action data and promoting the continuous update of the status of the digital twin production line.

[0062] The data driving module 303 generates animation data for each simulation device on the digital twin production line according to the action data provided by the simulation conversion module 302, and delivers it to the animation output module 303. The animation output module 303 generates and displays simulation animations based on the animation data. These simulation animations reflect the real-time status of each simulation device on the digital twin production line.

[0063] The statistical output module 304 is connected to the animation output module 303, and it saves the simulation animation in the form of video or picture. In this way, it is possible to retrieve all previous simulations later, to compare the differences between different production line design inputs, and to introduce new tools for further analysis of simulation results. For example, statistical methods or artificial intelligence can be used to process all previous simulations to obtain the best results, without being limited to manual tuning by designers in a single simulation.

[0064] See also Figure 3 The present invention also discloses a simulation method using a production line design simulation system using digital twin technology. A preferred embodiment thereof comprises the steps of:

[0065] Step S100, building a model.

[0066] Designers generate production line design inputs based on demand, and then use industrial modeling units to build logistics models and trafficability models based on the production line design inputs.

[0067] Step S101, initializing the digital twin unit.

[0068] The passability model is imported into the digital twin unit, and the digital twin unit completes initialization using the passability model.

[0069] Step S102, initializing the logistics simulation unit.

[0070] The logistics model is imported into the logistics simulation unit, and the logistics simulation unit completes initialization using the logistics model.

[0071] Step S103: the logistics simulation unit generates logistics process data.

[0072] The logistics simulation unit reads logistics parameters and generates logistics process data based on the logistics model.

[0073] Step S104, the digital twin unit reads the logistics process data.

[0074] Import logistics process data into the digital twin unit.

[0075] Step S105: Generate animation input parameters.

[0076] The simulation conversion module in the digital twin unit reads the logistics process data and converts it into animation input parameters.

[0077] Step S106, generating action data.

[0078] The simulation conversion module performs data interpolation based on the animation input parameters, supplements the information required by the simulation device, and generates action data for each corresponding simulation device.

[0079] Step S107, generating animation data.

[0080] The data-driven module in the digital twin unit reads the motion data and generates animation data for each simulated device.

[0081] Step S108, displaying the simulation animation.

[0082] The animation output module in the digital twin unit generates and displays simulation animation for each simulated device based on the animation data.

[0083] Step S109, obtaining the logistics status.

[0084] Based on the simulation animation, designers can obtain the logistics status of the digital twin production line under the current configuration.

[0085] Step S110, evaluating the logistics status.

[0086] The designer evaluates whether the logistics status meets the standards; if so, proceed to step S111; otherwise, after manually adjusting the logistics parameters, jump to step S103 and re-simulate.

[0087] Step S111, completing the production line design.

[0088] Read the current logistics model, throughput model and logistics parameters, determine the parameters designed for the current production line, and complete the production line design.

[0089] See also Figure 4In the present invention, after completing multiple simulations using the above steps, production line design can also be performed based on historical simulation data using statistical algorithms, which includes the steps of:

[0090] Step S200, reading all previous simulation animations.

[0091] Use the statistical output module in the digital twin unit to read the videos saved from previous simulation animations.

[0092] Step S201, extract flow status.

[0093] Use tool software to extract the corresponding logistics status from these videos.

[0094] Step S202, optimizing logistics parameters.

[0095] Each simulation contains multiple sets of logistics states. Multiple simulations mean more logistics states. Statistical tools or artificial intelligence are used to analyze all logistics states and select the optimal logistics parameters.

[0096] Step S203, determine the production line design.

[0097] According to the selected optimal logistics parameters, the corresponding logistics model and passability model are recorded, and then together with the logistics parameters, the production line design is finalized.

[0098] The statistical output module is used to select parameters in multiple simulations, which is more universal than the parameters obtained from a single simulation. When multiple production line designs have similar requirements, this method can obtain a more reasonable production line design faster than a single simulation. However, if a new production line design involves some new factors, the results of a single simulation are more reliable.

[0099] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A production line design simulation system using digital twin technology, characterized in that: It includes industrial modeling unit, logistics simulation unit and digital twin unit; The industrial modeling unit establishes a logistics model and a passability model based on the production line design input, and then sends the logistics model to the logistics simulation unit, and sends the passability model to the digital twin unit; The logistics simulation unit calculates logistics process data based on the initial logistics parameters and using the logistics model, and sends the logistics process data to the digital twin unit; The digital twin unit establishes a simulated production line according to the passability model, then receives the logistics process data, and displays the logistics status on the simulated production line in the form of a simulation animation; The designer generates new logistics parameters according to the logistics status and delivers them to the logistics simulation unit for a new round of iteration until the logistics status meets the design requirements.

2. The production line design simulation system using digital twin technology according to claim 1, characterized in that: The industrial modeling unit includes a logistics modeling module and a passability modeling module; The logistics modeling module generates the logistics model based on the production line design input, including logistics scheduling information in the production line; The passability modeling module generates the passability model based on the production line design input, which includes the movement information of each device and material on the production line.

3. The production line design simulation system using digital twin technology as claimed in claim 1, characterized in that: The logistics simulation unit includes a model import module, a parameter input module and a process simulation module; The model importing module initializes the process simulation module based on the logistics model, so that subsequent simulations are all based on the input logistics model; The parameter input module reads the logistics parameters and configures them into the process simulation module; The process simulation module calculates and obtains the logistics process data based on the logistics model and the logistics parameters.

4. The production line design simulation system using digital twin technology as claimed in claim 1, characterized in that: The digital twin unit includes a layout generation module, a simulation conversion module, a data driving module and an animation output module; The layout generation module reads the passability model, and generates simulation equipment on the digital twin production line according to the passability model; the simulation conversion module reads the logistics process data, performs data processing based on the logistics process data, generates action data for driving the simulation equipment, and sends it to the data driving module; The data driving module generates animation data corresponding to each of the simulation devices according to the action data; The animation output module generates and displays the simulation animation reflecting the real-time status of each simulation device according to the animation data.

5. The production line design simulation system using digital twin technology as claimed in claim 4, characterized in that: The digital twin unit also includes a statistical output module; the statistical output module extracts video from the simulation animation and saves it for later retrieval.

6. The production line design simulation system using digital twin technology according to any one of claims 4 or 5, characterized in that: The simulation device comprises a simulation conveyor belt and a simulation robot.

7. The production line design simulation system using digital twin technology according to any one of claims 4 or 5, characterized in that: The data processing of the simulation conversion module includes data interpolation.

8. A simulation method using the production line design simulation system using digital twin technology as claimed in claim 1, characterized in that: Contains steps: Step S10, establishing the logistics model and the trafficability model respectively using the industrial modeling unit according to the production line design input; Step S11, importing the passability model into the digital twin unit; Step S12, importing the logistics model into the logistics simulation unit; Step S13, using a logistics simulation unit to read logistics parameters and generate the logistics process data based on the logistics model; Step S14, importing the logistics process data into the digital twin unit; Step S15, the digital twin unit generates and displays a simulation animation in combination with the passability model and the logistics process data; Step S16, the designer obtains the logistics status according to the simulation animation; Step S17, the designer evaluates whether the logistics status meets the standard; if it meets the standard, go to step S18, otherwise after adjusting the logistics parameters, jump to step S13; Step S18, completing the production line design according to the logistics model, the passability model and the logistics parameters.

9. The simulation method of the production line design simulation system using the digital twin technology according to claim 8, characterized in that: Step S15 includes sub-steps: Step S151, the simulation conversion module in the digital twin unit reads the logistics process data and converts it into animation input parameters; Step S152, the simulation conversion module performs data interpolation based on the animation input parameters, supplements the information required by the simulation device, and generates action data for each corresponding simulation device; Step S153, the data driving module in the digital twin unit reads the action data and generates animation data for each of the simulation devices; Step S154: the animation output module in the digital twin unit generates and displays the simulation animation according to the animation data.

10. The simulation method of the production line design simulation system using the digital twin technology according to claim 8, characterized in that: It also includes a method for designing a production line based on historical simulation data, including the steps of: Step S20, using the statistical output module in the digital twin unit to read the videos saved from the previous simulation animations; Step S21, extracting the logistics status corresponding to the video; Step S22, performing statistical analysis on the logistics status to select the optimal logistics parameters; Step S23, completing the production line design according to the logistics model, the passability model and the logistics parameters.

Images