Digital twin virtual-real mapping method for discrete complex product assembly process

Abstract

The application discloses a digital twin virtual-real mapping method for a discrete complex product assembly process, analyzes a discrete assembly operation production line, decomposes production line elements and constructs an element set, combines three types of objects, namely, an assembly process, equipment operation and product state, according to the relationship between the elements, establishes corresponding virtual-real mapping rules for the three types of objects, establishes a "production line-product-state" correlation rule based on a hierarchical relationship for the relationship between the production line elements, finally obtains data, model files and data analysis models of a data center in a platform through an interactive engine of the integrated platform, realizes data interactive mapping between a virtual space and a physical space taking a three-dimensional model as a carrier, and expresses a discrete complex product workshop state through a system virtual model.

Description

Technical Field

[0001] This invention belongs to the technical field of digital twins, specifically relating to a digital twin virtual-real mapping method for the assembly process of discrete complex products. Background Technology

[0002] Virtual-real mapping technology, a key technology in the digital twin technology system, is under continuous research. Its application in continuous operation scenarios such as machining is relatively mature. However, for discrete and complex products, due to limitations in application scenarios and objects, the algorithms and rules used vary greatly, and currently, there is still no suitable virtual-real mapping rule. Especially considering the complexity and high discreteness of products in aircraft production and assembly processes, how to synchronously map the physical environment with the virtual world has become a pressing challenge for the application of digital twin technology in assembly workshops for discrete and complex products.

[0003] Therefore, this invention discloses a digital twin virtual-real mapping method for the assembly process of discrete complex products. Summary of the Invention

[0004] This invention discloses a digital twin virtual-real mapping method for the assembly process of discrete complex products, which realizes real-time and accurate mapping of the virtual environment to the physical environment. The virtual environment accurately and effectively expresses the physical state of the site, enabling managers to quickly grasp the workshop operation status information without having to go to the site to check the status, and assisting managers in making rapid decisions.

[0005] This invention is achieved through the following technical solution:

[0006] This paper proposes a digital twin virtual-physical mapping method for the assembly process of discrete complex products. It analyzes the discrete assembly production line, decomposes the production line elements, and constructs an element set. Based on the relationships between the elements, it forms three types of objects: assembly process, equipment operation, and product status. Corresponding virtual-physical mapping rules are established for these three types of objects. A hierarchical "production line-product-status" association rule is established for the relationships between production line elements. Finally, the interaction engine of the integration platform acquires data, model files, and data analysis models from the data platform, realizing data interaction mapping between the virtual space and physical space using a 3D model as the carrier. This allows the status of the discrete complex product production workshop to be expressed through the system's virtual model.

[0007] To better realize the present invention, the following steps are further included:

[0008] Step 1: Based on the elements covered by the assembly production line, establish a set of entity elements and a set of state elements;

[0009] Step 2: Classify assembly operations according to their content and mode, and establish virtual-real mapping rules for the classified objects;

[0010] Step 3: Based on the virtual-real mapping rules, establish hierarchical association rules between entity elements, state elements, and basic data;

[0011] Step 4: Obtain data, model files, and data analysis models from the platform through the platform's interaction engine, realize data interaction mapping between virtual and physical spaces using 3D models as carriers, and express the state of the production workshop for discrete and complex products through the system's virtual model.

[0012] To better realize the present invention, step 3 further includes:

[0013] Step 3.1: Determine whether there is a relationship between entity elements and state elements. If there is a relationship between entity elements and state elements, proceed to step 3.2.

[0014] Step 3.2: Use the analytic hierarchy process (AHP) to identify the mapping rules between state elements and entity elements;

[0015] Step 3.3: Analyze the business objects included in the status elements and associate the basic data corresponding to the business objects;

[0016] Step 3.4: Extract the corresponding fields from the basic data based on the display requirements of the status elements to form association rules.

[0017] To better realize the present invention, further, in step 3.4, the association rule between the state elements and the basic data is as follows:

[0018]

[0019] in: This represents the association rules between basic data and state elements; Y i (dd) indicates the display requirements for status elements; dd indicates basic data; DD indicates the basic dataset; ω i Indicates weight; This represents the i-th state element; represents the set of state elements; m represents the number of data in the basic dataset.

[0020] To better realize the present invention, step 2 further includes:

[0021] Step 2.1: Divide the assembly operations into manual operations and equipment-assisted testing categories;

[0022] Step 2.2: For manual operation categories, define the constituent units that form the product during manual assembly, decompose the materials contained in the constituent units, and establish a virtual mapping of constituent units-materials-operation manuals;

[0023] Step 2.3: For the equipment auxiliary test category, define the test units that make up the test process, decompose the test equipment included in the test unit, and establish a virtual mapping of test unit-test equipment-operation manual.

[0024] To better realize the present invention, further, in step 2.2, the virtual mapping function between materials and operation manuals is established as follows:

[0025]

[0026] in: A virtual mapping function representing the relationship between materials and operating manuals; This represents the j-th operation manual in the i-th category of operation manuals; This represents the j-th material in the i-th material category; s1, s2, and s3 represent the three status values ​​respectively; o1, o2, o3, and o4 represent the status values ​​of the operation manual. This indicates that a value will be retrieved from the user manual. This indicates that a value is being retrieved for the material.

[0027] To better realize the present invention, further, in step 2.2, the virtual mapping function between the constituent units, materials, and operation manual is established as follows:

[0028]

[0029] in: It represents the j-th component in the i-th component category; && represents logical AND.

[0030] To better realize the present invention, further, in step 2.3, the virtual mapping function established for the test unit-test equipment-operation manual is as follows:

[0031]

[0032] in: This represents the j-th test unit in the i-th test unit category; This represents the j-th test device in the i-th test device category; This represents the virtual space state of the j-th test unit in the i-th test unit category; state_bj1 represents the fixed display state; state_bj2 represents the normal motion trajectory display state; state_bj3 represents the abnormal motion trajectory display state; state_bj4 represents the no-display state; ac_ma2 represents the normal working state of the device; ac_ma3 represents the abnormal working state of the device. This represents the state of the j-th device in the i-th device category; This indicates the status of the j-th operation manual in the i-th category; ac_ao2 indicates the status of started but not completed; ac_ao3 indicates the status of completed but not archived; ac_ao4 indicates the status of completed and archived; r i This indicates the value to be mapped, which can be either 1 or 0.

[0033] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0034] (1) This invention accurately maps the physical environment of complex product production lines, taking into account the entities, data and status of each link and element of the production line, comprehensively representing the on-site operation status, and accurately expressing it through system virtual models and indicators, which is conducive to managers quickly obtaining on-site information.

[0035] (2) This invention expresses information about the actual state of the production line on-site, and the operational status information is easier to express than that of the dispersed business system. By using entity and status association, the on-site data is accurately mapped, which is conducive to providing customized and modular data reports through the established system and realizing lean management. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the process steps of the present invention. Detailed Implementation

[0037] Example 1:

[0038] This embodiment discloses a digital twin virtual-physical mapping method for the assembly process of discrete complex products. It analyzes the discrete assembly production line, decomposes the production line elements and constructs an element set. Based on the relationships between the elements, it forms three types of objects: assembly process, equipment operation, and product status. Corresponding virtual-physical mapping rules are established for these three types of objects. A hierarchical "production line-product-status" association rule is established for the relationships between production line elements. Finally, the interaction engine of the integration platform acquires data, model files, and data analysis models from the data platform, realizing data interaction mapping between the virtual space and physical space using a 3D model as the carrier. This allows the status of the discrete complex product production workshop to be expressed through the system's virtual model.

[0039] like Figure 1 As shown, the specific steps include:

[0040] Step 1: Based on the elements covered by the assembly production line, establish a set of entity elements and a set of state elements;

[0041] Step 2: Classify assembly operations according to their content and mode, and establish virtual-real mapping rules for the classified objects;

[0042] Step 3: Based on the virtual-real mapping rules, establish hierarchical association rules between entity elements, state elements, and basic data;

[0043] Step 4: Obtain data, model files, and data analysis models from the platform through the platform's interaction engine, realize data interaction mapping between virtual and physical spaces using 3D models as carriers, and express the state of the production workshop for discrete and complex products through the system's virtual model.

[0044] Furthermore, step 2 includes:

[0045] Step 2.1: Divide the assembly operations into manual operations and equipment-assisted testing categories;

[0046] Step 2.2: For manual operation categories, define the constituent units that form the product during manual assembly, decompose the materials contained in the constituent units, and establish a virtual mapping of constituent units-materials-operation manuals;

[0047] Step 2.3: For the equipment auxiliary test category, define the test units that make up the test process, decompose the test equipment included in the test unit, and establish a virtual mapping of test unit-test equipment-operation manual.

[0048] Furthermore, in step 2.2, the virtual mapping function between materials and the operation manual is established as follows:

[0049]

[0050] in: A virtual mapping function representing the relationship between materials and operating manuals; This represents the j-th operation manual in the i-th category of operation manuals; This represents the j-th material in the i-th material category; s1, s2, and s3 represent the three status values ​​respectively; o1, o2, o3, and o4 represent the status values ​​of the operation manual. This indicates that a value will be retrieved from the user manual. This indicates that a value is being retrieved for the material.

[0051] Furthermore, in step 2.2, the virtual mapping function between the constituent units, materials, and operation manuals is established as follows:

[0052]

[0053] in: It represents the j-th component in the i-th component category; && represents logical AND.

[0054] Furthermore, in step 2.3, the virtual mapping function established for the test unit-test equipment-operation manual is:

[0055]

[0056] in: This represents the j-th test unit in the i-th test unit category; This represents the j-th test device in the i-th test device category; This represents the virtual space state of the j-th test unit in the i-th test unit category; state_bj1 represents the fixed display state; state_bj2 represents the normal motion trajectory display state; state_bj3 represents the abnormal motion trajectory display state; state_bj4 represents the no-display state; ac_ma2 represents the normal working state of the device; ac_ma3 represents the abnormal working state of the device. This represents the state of the j-th device in the i-th device category; This indicates the status of the j-th operation manual in the i-th category; ac_ao2 indicates the status of started but not completed; ac_ao3 indicates the status of completed but not archived; ac_ao4 indicates the status of completed and archived; r i This indicates the value to be mapped, which can be either 1 or 0.

[0057] For any Its corresponding virtual space state is denoted as Fixed display, state_bj2: normal motion trajectory display, state_bj3: abnormal motion trajectory display, state_bj4: no display;

[0058] Functional Relationship middle For the installation of moving parts, For testing moving parts, this relationship indicates that testing can only be performed after the assembly of the corresponding parts is completed;

[0059]

[0060]

[0061]

[0062] Furthermore, step 3 includes:

[0063] Step 3.1: Determine whether there is a relationship between entity elements and state elements. If there is a relationship between entity elements and state elements, proceed to step 3.2.

[0064] Step 3.2: Use the analytic hierarchy process (AHP) to identify the mapping rules between state elements and entity elements;

[0065] Step 3.3: Analyze the business objects included in the status elements and associate the basic data corresponding to the business objects;

[0066] Step 3.4: Extract the corresponding fields from the basic data based on the display requirements of the status elements to form association rules.

[0067] Furthermore, in step 3.4, the association rules between state elements and basic data are as follows:

[0068]

[0069] in: This represents the association rules between basic data and state elements; Y i (dd) indicates the display requirements for status elements; dd indicates basic data; DD indicates the basic dataset; ω i Indicates weight; This represents the i-th state element; represents the set of state elements; m represents the number of data in the basic dataset.

[0070] Example 2:

[0071] This embodiment optimizes upon embodiment 1 and discloses a digital twin virtual-real mapping method for the assembly process of discrete complex products, specifically as follows:

[0072] Based on the elements encompassed by the assembly line, the content of the assembly line element set is defined. Expert methods are used to identify the production line elements, including physical elements and state elements. The content of the element set is then defined and expressed, with physical elements defined as ST. U The state element is ZT U ; indicates Line represents the element library of the entire production line. Represents the i-th type of entity element The j-th entity, Represents the m-th type of state element The nth state. Production line element combinations are denoted as {ST×ZT}, and the maximum number of combinations cannot exceed the "entity-state" generated by all entity elements under all state elements, i.e.

[0073] The assembly line operation content and operation mode are classified. Taking the aircraft as the product object, it can be divided into manual assembly process and equipment-assisted testing process. Entity element mapping rules are established for the above two parts respectively.

[0074] Establish virtual-physical mapping rules for the assembly process oriented towards manual operations. Define a compartment as a virtual component concept of the product. Each compartment includes finished products, wiring harnesses, conduits, and other materials to be installed. Each material is assigned to a specific component, and the operation is guided by an instruction manual to the operator. Define aircraft compartments (Space). U , Represents the i-th type of cabin The j-th compartment; the materials included in the compartment are denoted as Materia. U , Represents the i-th type of material The j-th one; the corresponding assembly operation manual is denoted as AO. FA , This represents the assembly operation manual for the i-th type. The jth book;

[0075] Virtual representation of cabin class, for any It has an inclusion relationship with the material, denoted as This means that any cargo compartment is a set consisting of all material types and their corresponding assembly operation manuals for that cargo compartment.

[0076] The assembly operation manual is presented virtually, arbitrarily. The status represents the actual progress of the work, including status values ​​such as not started, started but not completed, completed but not archived, and archived, denoted as .

[0077] To virtually represent materials, arbitrarily In a virtual environment, according to the corresponding The value is displayed in different states, including three states: not displayed, flashing display, and opaque display, denoted as .

[0078] pass and The correlation is established, and the mapping function is shown in Formula 1:

[0079]

[0080] The algorithm for virtual-real mapping in the cabin assembly process is established, and the code is shown below:

[0081]

[0082] For equipment-assisted testing processes, the virtual-real mapping rules require that the functional performance testing of aircraft moving parts be mapped to testing equipment and process documents. (Aircraft moving parts BJ) U , Represents the i-th type of test unit The j-th one; the corresponding test operation manual is denoted as AO. FT , Test operation manual for class i The j-th book; the required equipment control is denoted as Ma. U , This represents the j-th device of type i; a test unit is established. User Manual Test equipment The mapping function for the three is:

[0083]

[0084] The expert method is used to identify the entity and state elements of the production line, for any... Construct the correlation matrix X = (x i,j ) m×n Based on the actual situation, any x ij The values ​​0, 1, and ∞ represent that entity element i and state element j have no association, have an association, and are unreachable, respectively. Therefore, the main diagonal element x of matrix X is... ij =∞, x ij =x ji ;

[0085] The Analytic Hierarchy Process (AHP) is used to identify the mapping rules for each state element, constructing a decision hierarchy of "goal layer - criterion layer - alternative layer," and evaluating and analyzing each layer to form the association rules between entity elements and state elements; for x ij ∈X and x ij The associated elements with a value of 1 are evaluated and analyzed one by one to obtain the display matrix S = (s i,j ) m×n Define any s ij The values ​​range from 0, 1, and 2, representing entity elements respectively. Corresponding state elements Do not display, display, and retain interface display;

[0086] Step M12: The association rules between state elements and basic data mainly adopt an object-oriented approach. First, the state elements are analyzed. The included business objects are denoted as OO = {oo i |i=1,2,…,n}, then organize the basic data such as master data and business data corresponding to the business objects and denote them as DD={dd x Based on the requirements of display dimensions of state elements (|x=1,2,…,m}), the corresponding fields of basic data are extracted to form a basic database. The association rules between state elements and basic data are as follows:

[0087]

[0088] Where the basic data dd and the state elements There is a relationship, record it as The display requirements for state elements are defined as functions Y(dd), with the i-th display requirement denoted as Y. i (dd), each display requirement is assigned an experience weight ω by an expert. i .

[0089] By utilizing the virtual-real mapping rules established above, a digital twin system for discrete complex products can be constructed, enabling virtual-real mapping and visualization of the entire process and multiple states of complex product assembly, including planning, production, risk warning, and anomaly maintenance.

[0090] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A digital twin virtual-real mapping method for the assembly process of discrete complex products, characterized in that, This paper analyzes discrete assembly production lines, decomposes production line elements and constructs element sets. Based on the relationships between elements, three types of objects are formed: assembly process, equipment operation, and product status. Corresponding virtual-physical mapping rules are established for these three types of objects. Hierarchical "production line-product-status" association rules are established for the relationships between production line elements. Finally, the paper uses the interaction engine of the integration platform to obtain data, model files, and data analysis models from the data platform. This enables data interaction mapping between virtual and physical spaces using a 3D model as the carrier, and expresses the status of the discrete complex product production workshop through the system's virtual model. Includes the following steps: Step 1: Based on the elements covered by the assembly production line, establish a set of entity elements and a set of state elements; Step 2: Classify assembly operations according to their content and mode, and establish virtual-real mapping rules for the classified objects; Step 3: Based on the virtual-real mapping rules, establish hierarchical association rules between entity elements, state elements, and basic data; Step 4: Obtain data, model files and data analysis models from the platform through the interaction engine of the integrated platform, realize the data interaction mapping between the virtual space and the physical space with the three-dimensional model as the carrier, and express the state of the production workshop of discrete complex products through the system virtual model; Step 3 includes: Step 3.1: Determine whether there is a relationship between entity elements and state elements. If there is a relationship between entity elements and state elements, proceed to step 3.

2. Step 3.2: Use the analytic hierarchy process (AHP) to identify the mapping rules between state elements and entity elements; Step 3.3: Analyze the business objects included in the status elements and associate the basic data corresponding to the business objects; Step 3.4: Extract the corresponding fields from the basic data based on the display requirements of the status elements to form association rules.

2. The digital twin virtual-real mapping method for the assembly process of discrete complex products according to claim 1, characterized in that, In step 3.4, the association rules between state elements and basic data are as follows: ;in: This represents the association rules between basic data and state elements; This indicates the display requirements for status elements; dd represents basic data; DD represents the basic dataset; Indicates weight; This represents the i-th state element; represents the set of state elements; m represents the number of data in the basic dataset.

3. The digital twin virtual-real mapping method for the assembly process of discrete complex products according to claim 1, characterized in that, Step 2 includes: Step 2.1: Divide the assembly operations into manual operations and equipment-assisted testing categories; Step 2.2: For manual operation categories, define the constituent units that form the product during manual assembly, decompose the materials contained in the constituent units, and establish a virtual mapping of constituent units-materials-operation manuals; Step 2.3: For the equipment auxiliary test category, define the test units that make up the test process, decompose the test equipment included in the test unit, and establish a virtual mapping of test unit-test equipment-operation manual.

4. The digital twin virtual-real mapping method for assembly processes of discrete complex products according to claim 3, characterized in that, In step 2.2, the virtual mapping function between materials and operation manuals is established as follows: ;in: A virtual mapping function representing the relationship between materials and operating manuals; This represents the j-th operation manual in the i-th category of operation manuals; represents the j-th material in the i-th material category; s1, s2, and s3 represent the three state values ​​respectively; o 1. o 2. o 3. o 4 represents the four status values ​​in the operation manual; This indicates that a value will be retrieved from the user manual. This indicates that a value is being retrieved for the material.

5. The digital twin virtual-real mapping method for assembly processes of discrete complex products according to claim 4, characterized in that, In step 2.2, the virtual mapping function between the constituent units, materials, and operation manuals is established as follows: in: It represents the j-th component in the i-th component category; && represents logical AND.

6. The digital twin virtual-real mapping method for assembly processes of discrete complex products according to claim 5, characterized in that, In step 2.3, the virtual mapping function established for the test unit-test equipment-operation manual is: ;in: This represents the j-th test unit in the i-th test unit category; This represents the j-th test device in the i-th test device category; This represents the virtual space state of the j-th test unit in the i-th test unit category; Indicates a fixed display state; This indicates the normal motion trajectory display status; This indicates the status of abnormal movement trajectory display; This indicates that the status is not displayed; Indicates the normal operating status of the equipment; Indicates an abnormal operating state of the equipment; This represents the state of the j-th device in the i-th device category; This indicates the state of the j-th operation manual within the i-th category of operation manuals; This indicates a work that has started but is not yet completed. This indicates a completed but not yet archived status. This indicates that the work is completed and archived; r i This indicates the value to be mapped, which can be either 1 or 0.

Images