Digital twin system construction method for large-scale stamping scene

Abstract

The invention discloses a digital twin system construction method for a large-scale stamping scene, and the method comprises a physical workshop layer which is used for collecting data related in the production process of a stamping production workshop, collecting the data through a sensing device, and adjusting the state of a system through a control strategy or algorithm; the geometric mechanism layer is used for mapping the production process and information data of the physical workshop layer in real time and performing state management and feedback on the physical workshop layer; and deploying an application layer: collecting and fitting various data information results of the physical workshop layer and the geometric mechanism layer, generating a control strategy through analogue simulation and optimization decision, and feeding back the control strategy to the physical workshop layer. The problems that a traditional stamping workshop is low in digitization degree and control lags behind are solved, and the production efficiency and the equipment reliability can be remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of digital twins for production and manufacturing processes, and in particular to a method for constructing a digital twin system for large-scale stamping scenarios. Background Art

[0002] Amidst the global wave of digitalization, digital twin technology, a cutting-edge scientific achievement, is being widely integrated into various industries and becoming a core driving force for high-quality economic and social development. This technology integrates multiple sources of information, including physical models, sensor data, and operational history, to accurately map and reconstruct physical entities in virtual space. This fully reflects the entire lifecycle of physical equipment and enables two-way real-time interaction and synchronization between physical entities and virtual models, providing precise decision-making and optimization solutions for product design, manufacturing, and maintenance. Currently, stamping shops are facing shortcomings in models, data, and systems during their intelligent transformation. The integration of multi-source, heterogeneous data is difficult, leading to significant data redundancy and low utilization efficiency. Scenario construction is difficult and slow, resulting in poor modeling accuracy and insufficient lightweight processing capabilities, leading to underutilization of model assets. Furthermore, the mix of old and new equipment makes data collection from non-standard equipment challenging, while control systems are diverse, with complex interfaces and incompatible protocols. To overcome these bottlenecks, it is urgent to build a digital twin system for the stamping production process. This system will promote the deep integration of the stamping shop and the cyberspace, effectively resolve development difficulties, and significantly enhance the level of intelligence in the stamping shop. Summary of the Invention

[0003] In order to effectively solve the problems arising in the above-mentioned existing technologies, the present invention proposes a method for constructing a digital twin system for large-scale stamping scenarios, which realizes real-time mapping and closed-loop control of the stamping workshop through the collaboration of the physical workshop layer, geometric mechanism layer and deployment application layer.

[0004] To achieve the above objectives, the technical solution of the present invention is: A method for constructing a digital twin system for large-scale stamping scenarios, including: Physical workshop layer: used to collect data involved in the production process of the stamping workshop and collect it through sensing equipment, and adjust the system status through control strategies or algorithms; Geometric mechanism layer: real-time mapping of the production process and information data of the physical workshop layer, and status management and feedback of the physical workshop layer; Deployment application layer: collects and fits various data information results of the physical workshop layer and geometric mechanism layer, generates control strategies through simulation and optimization decisions, and feeds back to the physical workshop layer.

[0005] Specifically, the physical workshop layer includes: Workshop production resources: equipment, raw materials, human resources, energy resources, information resources, warehouses and logistics in the production process of the stamping workshop; Sensing and processing entity: A component that collects environmental or system information through sensing devices and adjusts the system state using control strategies / algorithms.

[0006] Furthermore, the sensing and processing entity adopts a closed-loop control feedback mechanism, including: Perception component: preliminarily processes collected environmental or device data; Control component: Generates instructions from the preliminarily processed data based on the control algorithm and performs physical actions.

[0007] Furthermore, the perception component includes a controller and a sensor, and the control component includes a controller and an actuator. The actuator's output is fed back to the perception layer through the controller, and the controller implements real-time monitoring and adjustment to ensure that the system can self-adjust according to the actual status.

[0008] Specifically, the geometric mechanism layer includes: geometric model construction: constructing a three-dimensional geometric model of the stamping equipment and parts; Mechanism model construction: realize the matching of three-dimensional geometric model and control system and mechanism analysis.

[0009] Specifically, the mechanism analysis is to conduct an in-depth analysis of the physical mechanisms in the stamping process and convert these mechanisms into mathematical models and algorithms.

[0010] Specifically, the deployment application layer includes: Simulation layer: Use the digital twin system to perform simulation and predict the working status during the stamping process; Optimization decision layer: Make optimization decisions on the production process based on simulation results.

[0011] Furthermore, the deployed application layer interacts with a human-machine interface (HMI) by optimizing control instructions.

[0012] Beneficial effects of the present invention: This invention constructs a virtual digital workshop through a digital twin system, using digital twin technology as the core link connecting the digitization and intelligence of stamping workshops. This system not only enhances the visualization of the production process but also innovates management models: it not only maps the entire production process in real time and establishes a virtual-reality interactive interface, but also optimizes real-world production through virtual space adjustments, effectively reducing physical commissioning costs and the need for manual intervention. It provides workshops with data-driven decision-making support tools and enables intelligent management of production scheduling, process parameters, and equipment maintenance. Through technological innovation, this system has established a new production paradigm that integrates the virtual and the real. While promoting the digital and intelligent transformation of traditional stamping workshops, it also lays the technical foundation for the development of intelligent manufacturing in the context of Industry 4.0. Its replicable construction model will further accelerate the industrial implementation of the manufacturing metaverse. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. The drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. For those skilled in the art, other drawings can be obtained based on the drawings without paying any creative work.

[0014] Figure 1 This is a system architecture diagram of the present invention. DETAILED DESCRIPTION

[0015] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0016] like Figure 1 The method for building a digital twin system for large-scale stamping scenarios shown in FIG. 1 includes: Physical workshop layer: used to collect data involved in the production process of the stamping workshop and collect it through sensing equipment, and adjust the system status through control strategies or algorithms; Geometric mechanism layer: real-time mapping of the production process and information data of the physical workshop layer, and status management and feedback of the physical workshop layer; Deployment application layer: collects and fits various data information results of the physical workshop layer and geometric mechanism layer, generates control strategies through simulation and optimization decisions, and feeds back to the physical workshop layer.

[0017] The physical workshop layer mainly refers to the actual large-scale stamping workshop, which is the core area for receiving and storing raw materials and actual stamping production. It is also the basic source of production data in the twin system and the service object that ultimately needs to be optimized. It mainly consists of two parts: workshop production resources and perception and control entities.

[0018] The workshop production resources mentioned above mainly refer to the equipment, raw materials, human resources, energy resources, information resources, warehouses and logistics, etc. in the production process of the stamping workshop.

[0019] Sensing and processing entity: A component that collects environmental or system information through sensing devices and uses control strategies / algorithms to adjust system status. It consists of two parts: a sensing component and a control component. The sensing component consists of a controller and a sensor. The sensor collects environmental or device data, and the controller is the initial processing unit responsible for data preprocessing and preliminary decision-making. The control component consists of a controller and an actuator. The controller is the core decision-making unit that generates control instructions based on the algorithm, and the actuator receives the instructions and performs physical actions. The controller is typically a microcontroller, PLC (programmable logic controller), or computer. A closed-loop control feedback mechanism is used to feed the actuator output back to the perception layer for real-time monitoring and adjustment, ensuring that the system can self-adjust according to the actual state to achieve better control results. Perception data and control instructions are transmitted between different components via the workshop local area network. The workshop local area network refers primarily to the relevant basic network equipment in the stamping workshop system. Its main function is to provide real-time data communication guarantees for various production equipment and various levels of the system in the stamping workshop. Data transmission typically uses serial communication, bus systems, wireless communication, etc. The algorithm uses control algorithms such as PID control, fuzzy control, and machine learning algorithms, and uses state estimation models to describe and predict system states, which helps improve control accuracy and efficiency. The human-machine interface (HMI) interacts with operators through visual, touch, and sound methods to display system status and receive user instructions.

[0020] The geometric mechanism layer primarily refers to the digital model of the stamping shop in virtual space. It is the geometric mechanism virtual workshop corresponding to the physical workshop. Its main function is to map the production process and information data of the stamping shop in real time, and to manage and provide feedback on the status of the workshop equipment.

[0021] The geometric mechanism layer includes: geometric model construction: building a three-dimensional geometric model of the stamping equipment and parts; mechanism model construction: achieving matching between the three-dimensional geometric model and the control system and mechanism analysis.

[0022] Specifically, geometric model construction primarily refers to 3D modeling: using CAD software and 3D scanning technology to construct 3D geometric models of stamping equipment. These models should accurately reflect the equipment's structure, dimensions, and kinematic characteristics. Furthermore, component library construction involves establishing a component library for stamping equipment, including 3D models of the smallest unit parts, such as screws and nuts, for rapid access in subsequent simulations and simulations. The geometric mechanism workshop model primarily refers to the integration of the physical and digital worlds to enable comprehensive monitoring, analysis, and optimization of the stamping shop.

[0023] Specifically, the mechanism model construction mainly refers to control system matching: matching the components constructed by the geometric model with the machine actions of the control system to achieve the corresponding description of the actual motion trajectory of the equipment in the geometric model; and conducting in-depth analysis of the physical mechanisms in the stamping process, such as material deformation, flow and fracture, and converting these mechanisms into mathematical models and algorithms.

[0024] The deployment application layer's primary function is to directly address the functional requirements of users and the actual stamping shop production process. It collects and integrates various data and information results from the physical shop floor and geometric mechanism layers, providing corresponding service functions. The deployment application layer plays a crucial role in modern software architecture. By providing clear interfaces, encapsulating complex business logic, and supporting system integration, it helps build maintainable, scalable, and secure enterprise-level applications. The deployment application layer interacts with the human-machine interface (HMI) by optimizing control instructions.

[0025] Specifically, the deployment application layer includes: a simulation layer, which uses a digital twin system to perform simulation and predict the working conditions during the stamping process, such as material deformation, equipment wear and energy consumption; an optimization decision layer, which makes optimization decisions on the production process based on the simulation results, such as adjusting stamping parameters and optimizing equipment layout.

[0026] The above description is merely a preferred embodiment of the present invention and does not constitute any form of limitation to the present invention. Although the present invention has been disclosed as above in terms of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can, without departing from the scope of the technical solution of the present invention, make some changes or modifications to equivalent embodiments using the technical contents disclosed above. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A method for constructing a digital twin system for large-scale stamping scenarios, characterized in that: include: Physical workshop layer: used to collect data involved in the production process of the stamping workshop and collect it through sensing equipment, and adjust the system status through control strategies or algorithms; Geometric mechanism layer: real-time mapping of the production process and information data of the physical workshop layer, and status management and feedback of the physical workshop layer; Deployment application layer: collects and fits various data information results of the physical workshop layer and geometric mechanism layer, generates control strategies through simulation and optimization decisions, and feeds back to the physical workshop layer.

2. The method for constructing a digital twin system according to claim 1, wherein: The physical workshop layer includes: Workshop production resources: equipment, raw materials, human resources, energy resources, information resources, warehouses and logistics in the production process of the stamping workshop; Sensing and processing entity: A component that collects environmental or system information through sensing devices and adjusts the system state using control strategies / algorithms.

3. The method for constructing a digital twin system according to claim 2, wherein: The sensing and processing entity adopts a closed-loop control feedback mechanism, including: Perception component: preliminarily processes collected environmental or device data; Control component: Generates instructions from the preliminarily processed data based on the control algorithm and performs physical actions.

4. The method for constructing a digital twin system according to claim 3, wherein: The perception component includes a controller and a sensor, and the control component includes a controller and an actuator. The actuator's output is fed back to the perception layer through the controller, and the controller implements real-time monitoring and adjustment to ensure that the system can self-adjust according to the actual status.

5. The method for constructing a digital twin system according to claim 1, wherein: The geometric mechanism layer includes: geometric model construction: constructing three-dimensional geometric models of stamping equipment and parts; Mechanism model construction: realize the matching of three-dimensional geometric model and control system and mechanism analysis.

6. The method for constructing a digital twin system according to claim 5, characterized in that: The mechanism analysis is to conduct an in-depth analysis of the physical mechanisms in the stamping process and convert these mechanisms into mathematical models and algorithms.

7. The method for constructing a digital twin system according to claim 1, wherein: The deployment application layer includes: Simulation layer: Use the digital twin system to perform simulation and predict the working status during the stamping process; Optimization decision layer: Make optimization decisions on the production process based on simulation results.

8. The method for constructing a digital twin system according to claim 1, wherein: The deployment application layer interacts with a human-machine interface (HMI) by optimizing control instructions.

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