Contour precision dynamic control system for part machining based on digital twinning

Abstract

The invention relates to the field of intelligent manufacturing, in particular to a digital twinning-based profile precision dynamic control system for part machining, which comprises a machining module for machining to obtain a part; the measuring module is used for measuring the sizes of the parts machined by the machining module and calculating errors, and the measuring module is further used for analyzing error value distribution of all the parts; the digital twinning module is used for constructing three-dimensional simulation of the part assembly model, and the digital twinning module is used for adjusting the size of the part assembly model based on the part errors, outputting performance expressions of parts with different errors after assembly and extracting part pairs with complementary relations; the control module is used for acquiring error value distribution of each part; and based on the complementary relation part pairs extracted by the digital twin module, the processing module is controlled to adjust the processing feed amount, and the error value distribution of the part pairs is adjusted, so that the error value distribution is concentrated in a fixed range meeting the complementary relation.

Description

Technical Field

[0001] The present invention relates to the field of intelligent manufacturing, and in particular to a dynamic control system for contour accuracy of parts processing based on digital twins. Background Art

[0002] The application of digital twin technology in industrial manufacturing stems from the integration and breakthroughs of multiple key technologies under the Industry 4.0 wave. With the widespread adoption of high-precision sensors and the Industrial Internet of Things (IIoT), real-time data collection from equipment has become possible. The maturity of CAD / CAE simulation tools and multi-physics modeling technologies has laid the foundation for virtual prototyping. 5G and edge computing have solved the problem of low-latency transmission and processing of massive amounts of data. Artificial intelligence and big data analytics have enabled the prediction of equipment health and process optimization. Furthermore, Digital Thread technology has broken down data barriers throughout the product lifecycle, while cloud computing and high-performance computing (HPC) provide the computing power for complex simulations. The coordinated development of these technologies has enabled digital twins to move from concept to industrial implementation, becoming a core enabling technology for predictive maintenance, virtual commissioning, and smart factory optimization.

[0003] In the field of mechanical manufacturing, part machining error refers to the deviation between the actual machined size, shape, or position and the theoretical design value. Its root cause can be traced back to various factors, including machine tools, cutting tools, processes, materials, and the environment. CNC machined (CNC) parts also have errors, although their accuracy is generally much higher than that of traditional machining methods. Errors are inevitable, such as residual material vibration, micro-deformation of machine tools, tool wear, and residual stress in the blank. Due to machining errors, when the machined parts are assembled, the performance of the assembled products often varies depending on the machining errors. Summary of the Invention

[0004] To solve the above problems, the present invention provides a dynamic control system for contour accuracy of parts processing based on digital twins, which is used to evaluate the error range of parts processing through digital twins, and use digital assembly analysis to evaluate the performance impact caused by errors, and guide the processing error range of each part so that after they are matched, they can reduce the performance impact brought by error complementation.

[0005] In order to achieve the above objectives, the technical solution of the present invention is as follows: A dynamic control system for contour accuracy of parts processing based on digital twins, comprising:

[0006] Processing module: used to process parts;

[0007] Measurement module: used to measure the dimensions of parts processed by the processing module and calculate the errors. The measurement module is also used to analyze the error distribution of each part;

[0008] Digital twin module: This module is used to construct a three-dimensional simulation of the parts assembly model. It adjusts the size of the parts assembly model based on part errors, performs finite element and motion simulation on the parts assembly model, outputs the performance of parts with different errors after assembly, and extracts part pairs with complementary relationships. A complementary relationship means that when both parts in the pair have a fixed range of errors, the performance is greater than when a single part in the pair has errors.

[0009] Control module: used to obtain the error value distribution of each part; based on the complementary relationship part pairs extracted by the digital twin module, the processing module is controlled to adjust the processing feed and the error value distribution of the part pairs so that the error value distribution is concentrated in a fixed range that satisfies the complementary relationship.

[0010] The above scheme has the following beneficial effects:

[0011] 1. In this solution, the measurement module can measure the error distribution during the actual part processing process. Although errors are inevitable, the error distribution can be shifted as a whole by changing the processing feed of the processing module to improve the applicability of the error.

[0012] 2. In this solution, the digital twin module can be used to construct a three-dimensional simulation of the parts assembly model, so that the virtual part dimensions can be used in the three-dimensional simulation to perform finite element and motion simulation, and then analyze the performance of the assembly. During the processing process, the errors of the parts should be controlled within a certain preset range to ensure the final performance. When the preset range of the part error is exceeded, it will have an impact on the final performance. However, the errors may be complementary. That is, when the part pair has a fixed range of errors, the performance is better than the case where a part pair has an error in a single part. When the error distribution of the parts in the assembly meets certain rules, even if the part error exceeds the preset range, the final performance requirements can still be achieved.

[0013] The control module adjusts the processing feed of the processing module based on the part pairs with complementary relationships extracted by the digital twin module. By shifting the error value range and utilizing the complementary relationship of the part pairs, it can increase the probability of assembling parts that meet the final performance requirements within the error value range, reduce the proportion of defective products that need to be discarded or reprocessed, improve part utilization efficiency, and improve the cost consumption caused by defective products.

[0014] Furthermore, the processing module includes a CNC machine tool and a printer, and the processing module is used to generate an identification code for identifying the identity of the part.

[0015] Beneficial effects: CNC machine tools can complete machining under preset programs, making it easier for the control module to dynamically adjust the machining feed rate. The identification code can provide identity recognition capabilities, thereby tracing part information during production.

[0016] Furthermore, the measurement module is also used to scan the identification code, obtain the part identity information, and bind the measured error result with the identification code.

[0017] Beneficial effect: After measurement, the measurement module can bind and store the error results of the parts based on the part identity information, which is convenient for subsequent traceability and use.

[0018] Furthermore, the digital twin module is also used to scan the identification code of each part in the parts group to be assembled, read the error value of each part based on the identification code, and output the performance after assembly according to the error value of each part.

[0019] Beneficial effect: When the operator performs assembly work, he or she first scans the identification code of each part, and then uses the three-dimensional simulation results in the digital twin module to evaluate the assembly effect, making it easier for the operator to select parts that meet the requirements.

[0020] Furthermore, when the digital twin module outputs the performance after assembly, it determines whether the group of parts to be assembled meets the assembly performance requirements based on the preset performance standards; when the group of parts to be assembled does not meet the assembly performance requirements, an alarm is issued.

[0021] Beneficial effects: After the digital twin module outputs performance, it will determine whether the assembly performance requirements are met based on the preset performance standards. If not, an alarm will be issued to remind the operator to make adjustments to the parts selection.

[0022] Furthermore, it is characterized in that when the group of parts to be assembled does not meet the assembly performance requirements, the digital twin module reads the error results of each part in the group of parts to be assembled and determines whether there are parts that cause the error that does not meet the assembly performance requirements.

[0023] Beneficial Effect: When an operator needs to make a part selection adjustment, they first need to determine which part to replace. The digital twin module uses the error results of each part to determine the part that causes the error to not meet the assembly performance requirements, allowing the operator to quickly select and complete the part adjustment.

[0024] Furthermore, after the digital twin module determines the parts that cause errors that do not meet the assembly performance requirements, it adjusts the model size of the parts that cause errors that do not meet the assembly performance requirements in the parts assembly model, and obtains the error replacement range of each part that meets the assembly performance requirements.

[0025] Beneficial Effects: After determining the parts that need replacement, the replacement range must also be determined to avoid wasted work time caused by parts not within the machined part. The digital twin module adjusts the model dimensions of parts that cause errors that do not meet assembly performance requirements to determine the replacement range for each part that meets the assembly performance requirements, thereby further developing feasible replacement solutions.

[0026] Furthermore, after obtaining the error replacement range of each part that meets the assembly performance requirements, the error replacement range of each part is brought into the numerical distribution of each part error. The expected number of parts within the error replacement range of each part is selected based on probabilistic calculation. The digital twin module is used to select the part replacement scheme with the smallest sum of the expected number of selections for each part and output it.

[0027] Beneficial Effect: While it is possible to identify replacement parts from machined parts, the error distribution of these parts is often uneven, with the resulting parts concentrated within a specific range. Therefore, further optimization is required to quickly select parts that meet assembly performance requirements.

[0028] Furthermore, the digital twin module is also used to record the identification code of the replaced part. When the recorded part meets the assembly performance requirements of the part group to be assembled, and the corresponding type of part in the part group to be assembled is closer to the error value distribution concentration range than the recorded part, the digital twin module issues a prompt.

[0029] Beneficial effect: After the replacement is completed, the corresponding parts of the original set of parts to be assembled will be removed. When the error of the removed parts is close to the concentrated range of the error value distribution, it means that they have better adaptability and are more likely to be used in the set of parts to be assembled. However, when the error of the removed parts is far away from the concentrated range of the error value distribution, it means that it is more difficult to find a suitable set of parts to be assembled. Therefore, when the recorded parts meet the assembly performance requirements of the set of parts to be assembled, and the corresponding type of parts in the set of parts to be assembled are closer to the concentrated range of the error value distribution than the recorded parts. The parts in the set of parts to be assembled are replaced with the recorded parts, so that the errors of the recorded parts can gradually approach the concentrated range of the error value distribution, so that each part can find a matching set of parts.

[0030] Furthermore, when the recorded parts still do not meet the assembly performance requirements after passing through a preset number of parts groups to be assembled, the control module reads the recorded part errors and controls the processing module to adjust the processing feed rate to reduce the distribution of the part error values in the recorded part errors.

[0031] Beneficial effect: When a recorded part cannot find a matching set of parts to be assembled for a long time, it means that it is extremely difficult to be used and should be classified as a defective product and eliminated. Therefore, the control module reads the error of the part that causes this situation and controls the processing module to adjust the processing feed to reduce the proportion of processed parts within this error range.

[0032] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a module diagram of an embodiment of a dynamic control system for contour accuracy of parts processing based on digital twins of the present invention;

[0034] Figure 2 This is a logic diagram of machining feed adjustment of an embodiment of a dynamic control system for contour accuracy for parts machining based on digital twins of the present invention;

[0035] Figure 3 This is a logic diagram of part replacement in an embodiment of the contour accuracy dynamic control system for part processing based on digital twins of the present invention. DETAILED DESCRIPTION

[0036] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0037] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0039] The following is further described in detail through specific implementation methods:

[0040] Example 1:

[0041] As attached Figure 1-Figure 3 Shown: A dynamic control system for contour accuracy of parts processing based on digital twins, including:

[0042] Processing module: The processing module includes a CNC machine tool and a printer. The processing module is used to process parts and generate an identification code for identifying the identity of the parts.

[0043] Measurement module: used to measure the dimensions of parts processed by the processing module and calculate errors. The measurement module is also used to analyze the error distribution of each part. The measurement module is also used to scan the identification code, obtain the part identity information, and bind the measured error results to the identification code.

[0044] Digital twin module: used to construct a three-dimensional simulation of the parts assembly model. The digital twin module is used to adjust the size of the parts assembly model based on the part errors, perform finite element and motion simulation on the parts assembly model, output the performance of parts with different errors after assembly, and extract part pairs with complementary relationships. The complementary relationship is that when both parts pairs have a fixed range of errors, the performance is greater than the part pair with errors in a single part of the part pair.

[0045] The digital twin module is also used to scan the identification code of each part in the parts group to be assembled, read the error value of each part based on the identification code, and output the performance after assembly according to the error value of each part; the digital twin module judges whether the parts group to be assembled meets the assembly performance requirements based on the output performance and the preset performance standards; when the parts group to be assembled does not meet the assembly performance requirements, an alarm is issued, and the error results of each part in the parts group to be assembled are read at the same time, and it is judged that there are parts that cause errors that do not meet the assembly performance requirements, and then the model size of the parts that cause errors that do not meet the assembly performance requirements is adjusted in the parts assembly model, and the error replacement range of each part that meets the assembly performance requirements is obtained, and it is judged whether the current parts can meet the performance requirements after the parts group to be assembled by performing the replacement operation.

[0046] After obtaining the error replacement range of each part that meets the assembly performance requirements, the error replacement range of each part is brought into the numerical distribution of each part error. Based on probabilistic calculation, the expected number of parts within the error replacement range of each part is selected. The digital twin module is used to select the part replacement plan with the smallest sum of the expected number of selections for each part and output it.

[0047] Control module: used to obtain the error value distribution of each part; based on the complementary relationship part pairs extracted by the digital twin module, the processing module is controlled to adjust the processing feed and the error value distribution of the part pairs so that the error value distribution is concentrated in a fixed range that satisfies the complementary relationship.

[0048] During use, the measurement module can measure the error distribution in the actual part processing process. Although errors are inevitable, the overall error distribution can be shifted by changing the processing feed of the processing module to improve the applicability of the error. For example, if the processing feed is 1, an error of ±0.05 will be generated, and the error distribution will be between 0.95-1.05. If the feed is changed to 1.05, the error distribution will be between 1-1.1, thereby changing the overall distribution of the part processing.

[0049] The digital twin module can be used to construct a three-dimensional simulation of the parts assembly model, thereby using virtual part dimensions in the three-dimensional simulation to perform finite element and motion simulation, and then analyze the performance of the assembly. During the processing process, the errors of the parts should be controlled within a certain preset range to ensure the final performance. When the preset error range of the parts is exceeded, it will have an impact on the final performance. However, the errors may be complementary. That is, when the part pairs have a fixed range of errors, the performance is better than the case where a part pair has an error in a single part. Therefore, when the error distribution of the parts in the assembly meets certain rules, even if the part errors exceed the preset range, the final performance requirements can still be achieved.

[0050] The control module adjusts the processing feed of the processing module based on the part pairs with complementary relationships extracted by the digital twin module. By shifting the error value range and utilizing the complementary relationship of the part pairs, it can increase the probability of assembling parts that meet the final performance requirements within the error value range, reduce the proportion of defective products that need to be discarded or reprocessed, improve part utilization efficiency, and improve the cost consumption caused by defective products.

[0051] CNC machine tools can complete machining according to preset programs, allowing the control module to dynamically adjust the machining feed rate. Identification codes provide identity recognition, enabling traceability of part information during production. After measurement, the measurement module can bind and store error results based on part identity information for easy traceability and use.

[0052] When performing assembly work, the operator first scans the identification code of each part. Then, the assembly effect is evaluated using the 3D simulation results in the digital twin module, which facilitates the operator to select parts that meet the requirements. After the digital twin module outputs the performance results, it will determine whether the assembly performance requirements are met based on the preset performance standards. If not, an alarm will be issued to remind the operator to adjust the part selection. When the operator needs to adjust the part selection, they must first determine which part to replace. The digital twin module will use the error results of each part to determine the part that causes the error that does not meet the assembly performance requirements, allowing the operator to quickly select and complete the part adjustment.

[0053] After determining the parts that need to be replaced, the replacement range must also be determined to avoid wasted work time caused by the replacement range not being within the processed parts. The digital twin module can adjust the model size of the parts that cause the error that does not meet the assembly performance requirements to obtain the error replacement range values of each part that meet the assembly performance requirements, thereby further obtaining a feasible replacement plan. Although it is possible to find parts that meet the replacement requirements from the processed parts, the error value distribution of the processed parts is uneven in most cases, and the processed parts will be concentrated in one range. Therefore, further optimization is performed on the replacement plan to select parts that can quickly match the assembly performance requirements.

[0054] The operator's work steps are as follows: first, they pick up the parts group to be assembled and scan the identification code of each part in the group. The digital twin module will indicate whether the group meets the performance requirements after assembly. If so, assembly can begin. If not, the digital twin module will output the type of part that needs to be replaced. The operator replaces the corresponding part according to the part type output by the digital twin module and scans it again until the digital twin module indicates that the performance requirements after assembly are met. At this point, assembly can begin.

[0055] Example 2:

[0056] The difference from the above embodiment is that the digital twin module is also used to record the identification code of the replaced part. When the recorded part meets the assembly performance requirements of the part group to be assembled, and the corresponding type of part in the part group to be assembled is closer to the error value distribution concentration range than the recorded part, the digital twin module issues a prompt.

[0057] When the recorded parts still do not meet the assembly performance requirements after passing through a preset number of parts groups to be assembled, the control module reads the recorded part errors and controls the processing module to adjust the processing feed to reduce the distribution of the part error values in the recorded part errors.

[0058] After the replacement is completed, the corresponding parts of the original set of parts to be assembled will be removed. When the error of the removed parts is close to the concentrated range of the error value distribution, it means that they have better adaptability and are more likely to be used in the set of parts to be assembled. However, when the error of the removed parts is far away from the concentrated range of the error value distribution, it means that it is more difficult to find a suitable set of parts to be assembled. Therefore, when the recorded parts meet the assembly performance requirements of the set of parts to be assembled, and the corresponding type of parts in the set of parts to be assembled are closer to the concentrated range of the error value distribution than the recorded parts. The parts in the set of parts to be assembled are replaced with the recorded parts, so that the errors of the recorded parts can gradually approach the concentrated range of the error value distribution, so that each part can find a matching set of parts.

[0059] When a recorded part cannot find a matching set of parts to be assembled for a long time, it means that it is extremely difficult to be used and should be classified as a defective product and eliminated. Therefore, the control module reads the error of the part that causes this situation and controls the processing module to adjust the processing feed to reduce the proportion of processed parts within this error range.

[0060] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A dynamic control system for contour accuracy of parts processing based on digital twin, characterized in that: include: Processing module: used to process parts; Measurement module: used to measure the dimensions of parts processed by the processing module and calculate the errors. The measurement module is also used to analyze the error distribution of each part; Digital twin module: This module is used to construct a three-dimensional simulation of the parts assembly model. It adjusts the size of the parts assembly model based on part errors, performs finite element and motion simulation on the parts assembly model, outputs the performance of parts with different errors after assembly, and extracts part pairs with complementary relationships. A complementary relationship means that when both parts in the pair have a fixed range of errors, the performance is greater than when a single part in the pair has errors. Control module: used to obtain the error value distribution of each part; Based on the complementary part pairs extracted by the digital twin module, the control processing module adjusts the processing feed and adjusts the error value distribution of the part pairs so that the error value distribution is concentrated in a fixed range that satisfies the complementary relationship.

2. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 1, characterized in that: The processing module includes a CNC machine tool and a printer, and is used to generate an identification code for identifying the identity of the part.

3. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 2, characterized in that: The measurement module is also used to scan the identification code, obtain the part identity information, and bind the measured error result with the identification code.

4. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 3 is characterized in that: The digital twin module is also used to scan the identification code of each part in the parts group to be assembled, read the error value of each part based on the identification code, and output the performance after assembly based on the error value of each part.

5. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 4 is characterized in that: When the digital twin module outputs the performance after assembly, it determines whether the group of parts to be assembled meets the assembly performance requirements based on the preset performance standards; when the group of parts to be assembled does not meet the assembly performance requirements, an alarm is issued.

6. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 5, characterized in that: When the group of parts to be assembled does not meet the assembly performance requirements, the digital twin module reads the error results of each part in the group of parts to be assembled and determines whether there are parts that cause the error to not meet the assembly performance requirements.

7. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 6, characterized in that: After the digital twin module determines the parts that cause errors that do not meet the assembly performance requirements, it adjusts the model size of the parts that cause errors that do not meet the assembly performance requirements in the parts assembly model, and obtains the error replacement range of each part that meets the assembly performance requirements.

8. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 7, characterized in that: After obtaining the error replacement range of each part that meets the assembly performance requirements, the error replacement range of each part is brought into the numerical distribution of each part error. Based on probabilistic calculation, the expected number of parts within the error replacement range of each part is selected. The digital twin module is used to select the part replacement plan with the smallest sum of the expected number of selections for each part and output it.

9. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 8, characterized in that: The digital twin module is also used to record the identification code of the replaced parts. When the recorded parts meet the assembly performance requirements of the parts group to be assembled, and the corresponding type of parts in the parts group to be assembled are closer to the error value distribution concentration range than the recorded parts, the digital twin module will issue a prompt.

10. The dynamic control system for contour accuracy of parts processing based on digital twin according to claim 9, characterized in that: When the recorded parts still do not meet the assembly performance requirements after passing through a preset number of parts groups to be assembled, the control module reads the recorded part errors and controls the processing module to adjust the processing feed to reduce the distribution of the part error values in the recorded part errors.

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