Discrete manufacturing-oriented production unit total element digital twinning system

Abstract

The invention relates to the technical field of intelligent manufacturing, in particular to a discrete manufacturing oriented production unit total factor digital twinning system, which comprises a digital twinning system and is used for realizing virtual mapping of discrete manufacturing production units, and the digital twinning system comprises a three-dimensional scene construction unit, a virtual environment corresponding to a physical production unit in a 1: 1 manner is created, and the virtual environment is used for realizing virtual mapping of the discrete manufacturing production units; model vertex capturing and aligning functions are realized; the equipment model library unit comprises digital models of an industrial robot, a numerical control machine tool, conveying equipment and a clamp, and physical attribute parameters are configured; the multi-protocol communication interface unit integrates Modbus TCP, S7 and OPC UA protocols and is connected with the PLC and a robot control system; through high-precision three-dimensional modeling, multi-protocol real-time communication, containerization motion control and virtual-real synchronization technologies, digital mapping and collaborative optimization of production units are realized, the production line planning efficiency and the operation reliability are remarkably improved, the debugging cost is reduced, and full-life-cycle management is supported.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, specifically to a full-element digital twin system for production units in discrete manufacturing. Background Technology

[0002] With the rapid development of Industry 4.0 and intelligent manufacturing, digital twin technology has become a core driving force for the digital transformation of the manufacturing industry. In the field of discrete manufacturing, production units are typically composed of various heterogeneous equipment such as industrial robots, CNC machine tools, and conveying equipment, characterized by complex processes, diverse equipment, and flexible layout. According to public information (CN119439907A), a method and system for constructing an intelligent manufacturing production line for automobile wheel hubs based on digital twins is disclosed. This technology discloses the following steps in the production line construction method: two-dimensional planar layout design of the physical production line for automobile wheel hub manufacturing; three-dimensional geometric and physical attribute modeling of the production units of the physical production line for automobile wheel hub manufacturing; importing the three models of the production units of the automobile wheel hub manufacturing line into digital twin simulation software and completing the digital twin production line layout; this automobile wheel hub production system based on digital twins, through digital twin technology, uses automobile wheel hub processing, grinding, and inspection processes as the main line to construct a digital twin system for an intelligent manufacturing production line for automobile wheel hubs, realizing the digitalization, intelligentization, networking, and visualization of automobile wheel hub production; and through monitoring, prediction, analysis, and diagnostic functions, improving the production efficiency and control capabilities of automobile wheel hub manufacturing enterprises, and realizing intelligent manufacturing of automobile wheel hubs. The lack of a high-precision real-time data synchronization mechanism between physical equipment and virtual models makes it difficult for virtual debugging results to accurately guide actual production, resulting in long on-site installation and debugging cycles and low efficiency. Secondly, collaborative control between heterogeneous equipment is difficult. Since industrial robots, CNC machine tools and other equipment use different control systems and communication protocols, it is difficult to achieve integrated control and logic verification under a unified platform, which affects the overall operating efficiency and flexibility of the production line. Furthermore, traditional simulation systems cannot fully reproduce the physical characteristics and motion constraints of the actual production environment, resulting in deviations between virtual verification results and actual operation. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a full-element digital twin system for production units in discrete manufacturing. Through high-precision 3D modeling, multi-protocol real-time communication, containerized motion control, and virtual-real synchronization technology, it achieves digital mapping and collaborative optimization of production units, significantly improving production line planning efficiency and operational reliability, reducing debugging costs, and supporting full lifecycle management.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a full-element digital twin system for discrete manufacturing production units, comprising a digital twin system and used to realize the virtual mapping of discrete manufacturing production units, the digital twin system comprising: The 3D scene construction unit creates a virtual environment that corresponds to the physical production unit in a 1:1 ratio, and has the function of model vertex snapping and alignment. The equipment model library unit includes digital models of industrial robots, CNC machine tools, conveying equipment, and fixtures, and configures their physical attribute parameters; Multi-protocol communication interface unit, integrating Modbus TCP, S7 and OPC UA protocols, connects PLC and robot control system; The motion control engine unit uses containerization technology to encapsulate the device motion logic, including object containers and program containers; The real-time data synchronization unit establishes a mapping relationship between virtual signals and physical device I / O, and has deviation monitoring capabilities; A visual interactive platform that integrates layout design, logic programming, and simulation verification tools.

[0005] Preferably, the three-dimensional scene construction unit includes: The model capture and alignment module achieves precise alignment between models through geometric feature recognition technology, including three positioning modes: vertex matching, edge alignment, and planar fitting. The spatial measurement module provides multi-dimensional spatial relationship measurement functions, including precise calculation of discrete point spacing, point-to-line distance, line-to-line distance, and surface-to-surface distance; The layout export module converts 3D scene configuration information into standardized 2D engineering drawings containing device coordinates, orientation, and relative positions.

[0006] Preferably, the device model library unit includes: The 3D model import module is compatible with assembly model files in industry standard formats. The physical property configuration module allows you to set the model's material density, surface friction coefficient, and dynamic response parameters under gravity. The kinematic constraint module establishes the range of motion and kinematic constraints for translational and rotational joints.

[0007] Preferably, the multi-protocol communication interface unit includes: The industrial controller communication module enables read and write operations of data blocks for programmable logic controllers based on standard industrial protocols. The robot control interface module acquires robot joint data and end-effector pose through a dedicated interface; The signal conversion module establishes the mapping relationship between physical signals and virtual signals.

[0008] Preferably, the motion control engine unit includes: The motion object management module binds mechanical actuators to kinematic models and sets kinematic parameters, including joint limits, velocity curves, and acceleration constraints. The program execution module parses and executes industrial robot motion commands, including linear interpolation MoveL, joint space motion MoveJ, and circular interpolation MoveC commands. The logic processing module integrates basic logic operation functions, providing AND gates, OR gates, NOT gates, as well as time delay triggers and data storage registers.

[0009] Preferably, the motion object management module includes: Servo motion control components enable closed-loop position control and speed planning for linear motion axes, including position feedback interfaces and servo gain parameter configuration. The end effector control component manages the opening and closing motion control of the clamping mechanism, including setting travel limits, clamping force thresholds, and contact detection parameters; The machine vision positioning component integrates a camera imaging model and feature recognition algorithm, providing six-degree-of-freedom calculation of workpiece pose.

[0010] Preferably, the real-time data synchronization unit includes: The device status acquisition module acquires the operating status data of physical devices according to a preset sampling period; The virtual-to-real signal conversion module establishes a real-time mapping channel between floating-point position coordinates and Boolean control signals; The motion consistency verification module calculates and monitors the pose deviation between the virtual model and the actual device.

[0011] Preferably, the visual interactive platform includes: The 3D layout workspace provides a set of tools for adjusting the model's spatial pose, enabling translation, rotation, and geometric alignment of objects. The logical relationship configuration interface uses a visual connection method to build the control signal flow and data interaction relationship between devices; The robot virtual teaching device fully replicates the operation panel and programming functions of the actual teaching pendant.

[0012] This invention provides a full-element digital twin system for production units in discrete manufacturing. Compared with existing technologies, it has the following advantages: 1. A 1:1 virtual production line model is achieved through high-precision 3D scene construction units. The sub-millimeter positioning accuracy of the model capture and alignment module ensures the accuracy of equipment layout, and the multi-dimensional spatial analysis function of the spatial measurement module can detect potential interference problems in advance. The standardized models of the equipment model library unit and the precise parameter settings of the physical characteristic configuration module enable virtual debugging results to directly guide actual installation, reducing on-site debugging time. The containerization technology of the motion control engine unit enables rapid verification and iteration of control logic, and the motion command parsing capability of the program execution module ensures the accuracy of robot trajectory planning, significantly shortening the production line commissioning cycle.

[0013] 2. The real-time data acquisition capability of the multi-protocol communication interface unit and the millisecond-level latency of the real-time data synchronization unit ensure that the digital twin maintains a high degree of synchronization with the actual production line; the dynamic modeling of the motion object management module and the closed-loop control algorithm of the servo motion control module make the deviation between the virtual simulation results and the actual motion less than 1mm; the six-degree-of-freedom pose calculation function of the machine vision positioning module provides visual guidance for precision assembly, and the intelligent clamping control of the end effector control module can prevent workpiece damage, realize online optimization of process parameters, and improve production efficiency.

[0014] 3. The 3D layout workspace and logical relationship configuration interface of the visual interactive platform provide an intuitive human-computer interaction experience and support multi-disciplinary collaborative design; the complete teaching function of the robot virtual teaching device enables operators to be safely trained in a virtual environment, reducing training costs; the standardized engineering drawings and XML parameter storage of equipment model library units generated by the layout export module form a complete digital asset; the continuous monitoring function and deviation statistical charts of the motion consistency verification module provide data support for predictive maintenance; together, they build a full lifecycle digital management capability from design, debugging to operation and maintenance, improving the overall efficiency of equipment. Attached Figure Description

[0015] Figure 1 This is a block diagram of the digital twin system of the present invention; Figure 2 This is a block diagram of the three-dimensional scene construction unit in this invention; Figure 3 This is a block diagram of the device model library unit in this invention; Figure 4 This is a block diagram of the multi-protocol communication interface unit in this invention; Figure 5 This is a block diagram of the motion control engine unit in this invention; Figure 6 This is a block diagram of the motion object management module in this invention; Figure 7 This is a block diagram of the real-time data synchronization unit in this invention; Figure 8This is a block diagram of the visual interactive platform in this invention.

[0016] In the diagram: 1. Digital Twin System; 11. 3D Scene Construction Unit; 111. Model Capture and Alignment Module; 112. Spatial Measurement Module; 113. Layout Export Module; 12. Equipment Model Library Unit; 121. 3D Model Import Module; 122. Physical Property Configuration Module; 123. Kinematic Constraint Module; 13. Multi-Protocol Communication Interface Unit; 131. Industrial Controller Communication Module; 132. Robot Control Interface Module; 133. Signal Conversion Module; 14. Motion Control Engine Unit; 141. 1411 Motion Object Management Module; 1412 Servo Motion Control Component; 1413 End Effector Control Component; 1414 Machine Vision Positioning Component; 142 Program Execution Module; 143 Logic Processing Module; 15 Real-time Data Synchronization Unit; 151 Equipment Status Acquisition Module; 152 Virtual-Real Signal Conversion Module; 153 Motion Consistency Verification Module; 16 Visual Interaction Platform; 161 3D Layout Workspace; 162 Logic Relationship Configuration Interface; 163 Robot Virtual Teaching Device. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0018] Please see Figure 1 - As shown in the figure, this invention provides a technical solution: a full-element digital twin system for discrete manufacturing production units, including a digital twin system 1 used to realize the virtual mapping of discrete manufacturing production units. The digital twin system 1 includes: The 3D scene construction unit 11 creates a virtual environment that corresponds to the physical production unit 1:1, and has the function of model vertex snapping and alignment. Equipment model library unit 12 includes digital models of industrial robots, CNC machine tools, conveying equipment and fixtures, and configures physical attribute parameters; The multi-protocol communication interface unit 13 integrates Modbus TCP, S7 and OPC UA protocols to connect the PLC and the robot control system. The motion control engine unit 14 uses containerization technology to encapsulate the device motion logic, including object containers and program containers; The real-time data synchronization unit 15 establishes a mapping relationship between virtual signals and physical device I / O, and has a deviation monitoring function; The visual interactive platform 16 integrates layout design, logic programming, and simulation verification tools.

[0019] In this implementation scheme, the 3D scene construction unit 11 uses point cloud matching technology to construct a virtual workshop environment with millimeter-level precision, accurately restoring the equipment layout and production line topology; the equipment model library unit 12 integrates a standard equipment model library including six-axis articulated robots, five-axis machining centers, and roller conveyors, with each model containing precise geometric dimensions, mass attributes, and kinematic parameters; the multi-protocol communication interface unit 13 achieves real-time data exchange with the field PLC controller and robot control cabinet via industrial Ethernet, with a data acquisition frequency of up to 100Hz; the motion control engine unit 14 uses a microservice architecture to encapsulate equipment motion control algorithms, achieving synchronous control of virtual axes and physical equipment; the real-time data synchronization unit 15 ensures the motion consistency between the virtual model and the physical equipment through timestamp alignment and difference compensation algorithms, with a maximum latency of no more than 20ms; the visualization interaction platform 16 provides a complete toolchain from layout design and logic programming to virtual debugging, supports multi-user collaborative work and version management, and the final generated digital twin can be directly used for production line optimization and personnel training.

[0020] Specifically, the 3D scene construction unit 11 includes: The model capture and alignment module 111 achieves precise alignment between models through geometric feature recognition technology, including three positioning modes: vertex matching, edge alignment, and planar fitting. The spatial measurement module 112 provides multi-dimensional spatial relationship measurement functions, including accurate calculation of discrete point spacing, point-to-line distance, line-to-line spacing, and surface-to-surface distance; The layout export module 113 converts the 3D scene configuration information into standardized 2D engineering drawings containing device coordinates, orientation, and relative position.

[0021] In this embodiment, a high-precision virtual layout of production equipment is achieved through a model capture and alignment module 111. This module employs a feature-point-based intelligent matching algorithm, which automatically identifies vertex features, edge contours, and planar geometric features on the model surface when the user drags the equipment model. Sub-millimeter-level automatic alignment and positioning are achieved by calculating the least-squares fitting of the feature point cloud. The vertex matching mode is used for rapid docking of assembly interfaces, the edge alignment mode ensures the continuity of the conveyor line, and the planar fitting mode achieves precise positioning of the workbench. The space measurement module 112 integrates multiple spatial geometric calculation algorithms to calculate the installation spacing between equipment in real time during virtual debugging, including the collision avoidance distance between the robotic arm end and the tooling fixture, the parallelism detection of the conveyor line track spacing, and the verification of the safe space of the work area. The measurement results are displayed in real time in three-dimensional vector form. The layout export module 113 uses projection transformation-based technology to convert the three-dimensional scene data into a format compliant with GB / T. The A3-sized engineering drawings conforming to the 14689-2008 standard automatically label the absolute coordinates of each equipment base, the angular parameters of the equipment spindle orientation, and the relative dimensions between key equipment. At the same time, it generates a bill of materials containing equipment models and layout parameters, providing complete digital assembly guidance for on-site installation.

[0022] Specifically, the device model library unit 12 includes: 3D model import module 121, compatible with assembly model files in industry standard format; The physical property configuration module 122 sets the material density, surface friction coefficient, and dynamic response parameters of the model under gravity. Kinematic constraint module 123 establishes the range of motion and motion constraints for translational and rotational joints.

[0023] In this embodiment, the rapid import of various industrial equipment models is achieved through the 3D model import module 121. This module is developed based on the OpenCASCADE geometry kernel and supports importing STEP, IGES, and JT models. Assembly files in internationally recognized CAD formats such as Open are used to fully preserve the design benchmarks and assembly relationships of the original model. When importing CNC machine tool models, the hierarchical structure of key components such as the spindle and worktable is automatically identified. The physical property configuration module 122 adopts a physics-based modeling method to establish a mass attribute matrix for each equipment model. Users can set typical material density parameters such as 7.85 g / cm³ for steel and 2.7 g / cm³ for aluminum alloy for different materials, define friction coefficient ranges such as 0.6-0.8 for rubber and 0.15-0.25 for steel, and configure the dynamic response characteristics under a gravitational acceleration environment of 9.8 m / s². The kinematic constraint module 123 defines the 6-DOF joint motion range for the industrial robot by establishing a parameterized template for kinematic pairs, sets X / Y / Z axial travel limits for linear guides, and configures ±180° rotation constraints for rotary worktables. All motion parameters are stored in XML format and linked with the control program in real time to ensure that the virtual motion maintains strict dynamic consistency with the actual equipment.

[0024] Specifically, the multi-protocol communication interface unit 13 includes: Industrial controller communication module 131 implements data block read and write operations of programmable logic controller based on standard industrial protocols; The robot control interface module 132 acquires robot joint data and end-effector pose through a dedicated interface; Signal conversion module 133 establishes the mapping relationship between physical signals and virtual signals.

[0025] In this embodiment, a real-time data channel is established with the field PLC device through the industrial controller communication module 131. This module has built-in Modbus TCP, Profinet and EtherNet / IP industrial protocol stacks, and uses asynchronous IO to read and write the PLC's input / output image area and data blocks. Digital signals are processed in bit operation mode, and analog signals are converted through IEEE754 floating-point format. The robot control interface module 132 connects to the control system through the SDK development package provided by the robot manufacturer. It obtains the encoder values ​​of each joint of the six-axis robot in real time at a sampling frequency of 100Hz, calculates the pose matrix of the end effector of the robotic arm using the DH parameter method, and outputs the X / Y / Z coordinates and RPY attitude angle through quaternion conversion. The signal conversion module 133 constructs a virtual-real signal mapping table, maps the PLC's DI / DO points to virtual M register addresses, converts the robot's joint angles into virtual axis position data, and realizes the normalization processing of analog signals. All signal interaction processes use CRC-16 check to ensure the reliability of data transmission, and the communication status indicator is displayed in real time on the human-machine interface.

[0026] Specifically, the motion control engine unit 14 includes: The motion object management module 141 binds the mechanical actuator to the kinematic model and sets the kinematic parameters, including joint limits, velocity curves and acceleration constraints. The program execution module 142 parses and executes the industrial robot motion instructions, including linear interpolation MoveL, joint space motion MoveJ, and circular interpolation MoveC instructions. The logic processing module 143 integrates basic logic operation functions, providing AND gate, OR gate, NOT gate logic elements, as well as time delay triggers and data storage registers.

[0027] In this embodiment, a kinematic model of the equipment is established through the motion object management module 141. This module uses a modeling method based on DH parameters to establish a kinematic chain for the six-axis industrial robot, sets ±180° rotation limits for each joint, configures an S-shaped velocity curve to achieve smooth acceleration and deceleration, and calculates a singularity avoidance strategy using the Jacobian matrix. The program execution module 142 realizes real-time parsing of robot motion commands, performs path discretization processing on the MoveL linear interpolation command and calculates intermediate interpolation points, uses fifth-order polynomial interpolation for MoveJ joint spatial motion to ensure motion smoothness, and automatically calculates the center coordinates and transition corner speed when processing MoveC circular interpolation. The logic processing module 143 constructs a programmable control logic network, in which AND gates are used to determine safety interlock conditions, OR gates are used to handle multi-station selection logic, NOT gates are used to invert emergency stop signals, time delay triggers are used to precisely control the process cycle, and data registers store equipment operating status words and process parameters. All logic elements are connected in a visual manner to construct a control program equivalent to a PLC ladder diagram and generate a binary instruction set which is downloaded to the virtual controller for execution.

[0028] Specifically, the motion object management module 141 includes: The servo motion control component 1411 realizes closed-loop control of the position and speed planning of the linear motion axis, including the position feedback interface and servo gain parameter configuration; The end effector control component 1412 manages the opening and closing motion control of the clamping mechanism, including setting travel limits, clamping force thresholds, and contact detection parameters; The machine vision positioning component 1413 integrates a camera imaging model and feature recognition algorithm, providing six-degree-of-freedom calculation of workpiece pose.

[0029] In this embodiment, high-precision motion control is achieved through the servo motion control component 1411. This module uses a PID position closed-loop algorithm to control the linear motion axis, and has built-in feedforward compensation and notch filter to eliminate mechanical resonance. It can be configured with servo parameters such as proportional gain Kp=0.5-2.0 and integral time Ti=10-100ms, and receives feedback signals from the absolute encoder through the EnDat2.2 interface. The end effector control component 1412 manages the action timing of the pneumatic and electric grippers, sets the stroke range of 10-100mm and the clamping force threshold of 5-50N, and uses strain gauge signals to detect sudden changes in contact force. When workpiece slippage is detected, clamping force compensation is automatically triggered. The machine vision positioning component 1413 integrates the OpenCV vision library, calculates the three-dimensional pose of the workpiece in the camera coordinate system through the perspective n-point algorithm, and transforms it to the robot base coordinate system by combining the hand-eye calibration matrix. It outputs six-degree-of-freedom pose data of X / Y / Z translation and Rx / Ry / Rz rotation, with a positioning accuracy of ±0.1mm, which meets the visual guidance requirements of precision assembly.

[0030] Specifically, the real-time data synchronization unit 15 includes: The device status acquisition module 151 acquires the operating status data of the physical device according to a preset sampling period; The virtual-to-real signal conversion module 152 establishes a real-time mapping channel between floating-point position coordinates and Boolean control signals; The motion consistency verification module 153 calculates and monitors the pose deviation between the virtual model and the actual device.

[0031] In this embodiment, the device status acquisition module 151 polls the device status at a fixed period of 10ms. This module adopts a multi-threaded architecture to collect the PLC's IO status, robot joint angles, and sensor data in parallel, and ensures data synchronization through timestamp alignment. The virtual-real signal conversion module 152 constructs a bidirectional data channel, maps the PLC's BOOL type signals to virtual relay status, converts the encoder's 32-bit floating-point position value into virtual axis coordinates, and handles analog quantity range conversion and filtering. All signal transmissions adopt a producer-consumer model to ensure real-time performance. The motion consistency verification module 153 calculates the pose deviation between the virtual model and the actual device through a quaternion interpolation algorithm. When the detected position deviation exceeds 1mm or the angle deviation exceeds 0.5 degrees, an alarm is triggered, and the deviation trend curve is recorded for analysis of mechanical transmission errors. At the same time, the synchronization status indicator and deviation statistics chart are displayed in real time through the visualization interface of the digital twin platform.

[0032] Specifically, the visual interaction platform 16 includes: The 3D layout workspace 161 provides a set of tools for adjusting the model space pose, enabling translation, rotation, and geometric alignment of objects; The logical relationship configuration interface 162 constructs the control signal flow and data interaction relationship between devices through a visual connection method; The robot virtual teaching device 163 fully replicates the operation panel and programming functions of the actual teaching pendant.

[0033] In this embodiment, a virtual layout plan for the production line equipment is achieved through a 3D layout workspace 161. This workspace is developed based on the Unity3D engine, providing two operation modes: world coordinate system and local coordinate system. It supports precise translation (accuracy 0.1mm) and rotation (accuracy 0.1°) of the model via mouse dragging, and has an intelligent snap-fit ​​function to automatically align the conveyor line with the tooling fixture. The logic relationship configuration interface 162 adopts a node-based programming environment, allowing users to connect PLC input / output signals and actuator control points via dragging and dropping, establishing conditions containing AND, OR, and NOT logic. The system determines relationships and sets an adjustable delay trigger function from 0 to 10 seconds. All connection relationships are automatically generated to generate control logic code according to the IEC61131-3 standard. The robot virtual teaching device 163 fully simulates the operation experience of a real teaching pendant, including single-axis fine-tuning in the joint coordinate system, linear movement in the Cartesian coordinate system, and posture adjustment in the tool coordinate system. It supports online editing of MoveL / MoveJ / MoveC commands and real-time trajectory preview. It also has collision detection and singularity warning functions. All teaching programs can be directly exported as executable code files for the robot controller.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0035] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A full-element digital twin system for production units in discrete manufacturing, characterized in that: Including a digital twin system (1) and used to realize a virtual mapping of discrete manufacturing production units, the digital twin system (1) includes: The three-dimensional scene construction unit (11) creates a virtual environment that corresponds to the physical production unit 1:1 and has the function of model vertex capture and alignment. The equipment model library unit (12) includes digital models of industrial robots, CNC machine tools, conveying equipment and fixtures, and configures physical attribute parameters; The multi-protocol communication interface unit (13) integrates Modbus TCP, S7 and OPC UA protocols to connect the PLC and the robot control system; The motion control engine unit (14) uses containerization technology to encapsulate the device motion logic, including object containers and program containers; The real-time data synchronization unit (15) establishes a mapping relationship between virtual signals and physical device I / O, and has a deviation monitoring function; A visual interactive platform (16) integrates layout design, logic programming and simulation verification tools.

2. The full-element digital twin system for production units in discrete manufacturing according to claim 1, characterized in that: The three-dimensional scene construction unit (11) includes: The model capture and alignment module (111) achieves precise alignment between models through geometric feature recognition technology, including three positioning modes: vertex matching, edge alignment, and planar fitting. The spatial measurement module (112) provides multi-dimensional spatial relationship measurement functions, including accurate calculation of discrete point spacing, point-to-line distance, line-to-line distance and surface-to-surface distance; The layout export module (113) converts the 3D scene configuration information into standardized 2D engineering drawings containing device coordinates, orientation and relative position.

3. The full-element digital twin system for production units in discrete manufacturing according to claim 1, characterized in that: The device model library unit (12) includes: The 3D model import module (121) is compatible with assembly model files in industry standard formats; The physical property configuration module (122) sets the material density, surface friction coefficient, and dynamic response parameters of the model under gravity. The kinematic constraint module (123) establishes the range of motion and kinematic constraints for translational and rotational joints.

4. The full-element digital twin system for production units in discrete manufacturing according to claim 1, characterized in that: The multi-protocol communication interface unit (13) includes: The industrial controller communication module (131) implements data block read and write operations of the programmable logic controller based on the standard industrial protocol; The robot control interface module (132) acquires robot joint data and end-effector pose through a dedicated interface; The signal conversion module (133) establishes the mapping relationship between physical signals and virtual signals.

5. The full-element digital twin system for production units in discrete manufacturing according to claim 1, characterized in that: The motion control engine unit (14) includes: The motion object management module (141) binds the mechanical actuator to the kinematic model and sets the kinematic parameters, including joint limits, velocity curves and acceleration constraints. The program execution module (142) parses and executes industrial robot motion instructions, including linear interpolation MoveL, joint space motion MoveJ, and circular interpolation MoveC instructions; The logic processing module (143) integrates basic logic operation functions and provides AND gate, OR gate, NOT gate logic elements, as well as time delay triggers and data storage registers.

6. The full-element digital twin system for production units in discrete manufacturing according to claim 5, characterized in that: The motion object management module (141) includes: The servo motion control component (1411) realizes closed-loop position control and speed planning of the linear motion axis, including position feedback interface and servo gain parameter configuration; The end effector control assembly (1412) manages the opening and closing motion control of the clamping mechanism, including setting travel limits, clamping force thresholds and contact detection parameters; The machine vision positioning component (1413) integrates a camera imaging model and feature recognition algorithm to provide six-degree-of-freedom solution for workpiece pose.

7. The full-element digital twin system for production units in discrete manufacturing according to claim 1, characterized in that: The real-time data synchronization unit (15) includes: The device status acquisition module (151) acquires the operating status data of the physical device according to a preset sampling period; The virtual-to-real signal conversion module (152) establishes a real-time mapping channel between floating-point position coordinates and Boolean control signals; The motion consistency verification module (153) calculates and monitors the pose deviation between the virtual model and the actual device.

8. The full-element digital twin system for production units in discrete manufacturing according to claim 1, characterized in that: The visual interactive platform (16) includes: The 3D layout workspace (161) provides a set of tools for adjusting the model space pose, enabling translation, rotation and geometric alignment of objects; The logical relationship configuration interface (162) constructs the control signal flow and data interaction relationship between devices through a visual connection method; The robot virtual teaching device (163) fully replicates the operation panel and programming functions of the actual teaching device.

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