Low-altitude three-dimensional virtual simulation environment data visualization system

Abstract

The invention discloses a low-altitude three-dimensional virtual simulation environment data visualization system, and the system comprises a test bench digital infrastructure module which is used for carrying out model lightweight processing based on a refined design model, and constructing a high-precision three-dimensional digital pedestal of a test bench key structure; the mechanism model data interface module is used for packaging a multi-body dynamic model and a stress fatigue analysis model based on an FMI standard; the full three-dimensional visualization module is used for loading the three-dimensional digital base; and the integrated dispatching module is integrated with an accompanying simulation system, an evaluation analysis system and a visualization system. According to the invention, construction and simulation of a test bed and a unit mechanism model are realized, stress and fatigue analysis is carried out in combination with mechanical motion data, and multi-dimensional real-time rendering and presentation are carried out through a visual three-dimensional base. The system respectively runs in an independent computer, performs data communication through a data interface, and performs system integration and integration for a full-period integrated centralized control demand.

Description

Technical Field

[0001] This invention relates to a low-altitude three-dimensional virtual simulation environment data visualization system. Background Technology

[0002] Before conducting full-scale tests on the actual unit, simulation calculations are performed on the test bench and the unit to verify the safety of key systems in low-altitude three-dimensional scenarios and to predict the lifespan loss of key components after the test. This is of great importance.

[0003] Developing a visualization system for simulation data, combining the requirements of low-altitude 3D scenes, analyzing and integrating multibody dynamics models as well as strength and fatigue analysis models, providing simulation data for design conditions, and providing simulation operation of low-altitude 3D scene mechanism models will greatly promote the implementation of the project.

[0004] While existing technologies employ 3D modeling and simulation analysis, they fail to address the coordination issue between lightweight models and real-time stress rendering, and lack an integrated scheduling mechanism for multiple operating conditions. Existing technologies suffer from the following problems:

[0005] 1. Conflict between model accuracy and real-time performance: High-precision model rendering takes a long time, making it difficult to meet the requirements of real-time dynamic display;

[0006] 2. Insufficient integration of multi-source data: Heterogeneous data such as mechanical motion, stress, and power grid data lack a unified interface;

[0007] 3. Weak visualization and interactivity: Most systems only support static display and cannot dynamically display the safety status of key structures in multiple dimensions. Summary of the Invention

[0008] To address the problems existing in the prior art, the present invention aims to provide a low-altitude three-dimensional virtual simulation environment data visualization system. Through lightweight three-dimensional base construction, FMI standard data integration, real-time stress calculation and color rendering, and multi-screen linkage scheduling, it achieves multi-dimensional visualization of the entire experimental process.

[0009] To achieve the above objectives, the present invention provides a low-altitude three-dimensional virtual simulation environment data visualization system, comprising:

[0010] The test bench digital infrastructure module is used to perform lightweight model processing based on the refined design model and construct a high-precision three-dimensional digital base for the key structure of the test bench. The three-dimensional digital base covers multi-dimensional model data of the test bench's motor, mechanical, hydraulic, electrical and power grid simulators. The number of model faces does not exceed 60,000 and the number of components is not less than 30.

[0011] The mechanism model data interface module encapsulates multibody dynamics models and stress fatigue analysis models based on the FMI (Functional Mock-up Interface) standard, supports model exchange and co-simulation mode, and accesses JSON format simulation data packets via UDP protocol to achieve data integration of heterogeneous models from multiple fields;

[0012] The full 3D visualization module is used to load the 3D digital base and, based on stress calculation algorithms and vertex shading technology, drive the motion, stress and strain data of key structures to be rendered in real time in the form of multi-color cloud maps. The stress assessment and rendering time of the entire component is no more than 40ms.

[0013] The integrated scheduling module combines accompanying simulation, evaluation analysis, and visualization systems, supporting single-screen scheduling switching, three-screen linkage, and large-screen four-screen display for integrated application control of the experimental simulation platform.

[0014] Furthermore, the digital infrastructure module of the test bench uses CAD tools for forward model design and combines a 3D scanner for reverse correction. The lightweight model processing includes automatic mesh generation and PBR material mapping, with a texture resolution of no less than 512×512.

[0015] Furthermore, the mechanism model data interface module supports three co-simulation modes of the FMI standard: code export mode, tool coupling mode, and distributed mode. The distributed mode achieves cross-platform data interaction through the node server and client communication layer.

[0016] Furthermore, the stress calculation algorithm of the full 3D visualization module is implemented based on the Eigen library, and includes the following steps:

[0017] 1) Divide the component mesh into multiple triangular facets;

[0018] 2) Calculate the stress tensor of each node using linear algebra and generate stress distribution data based on the Mises stress formula;

[0019] 3) Using vertex shading technology, stress data is mapped to color values ​​and drawn on the surface of the 3D model in real time.

[0020] Furthermore, the vertex shading technique includes:

[0021] In UProceduralMeshComponent, assign color values ​​to the three vertices of each triangle.

[0022] Color interpolation rendering is implemented through the CreateMeshSection_LinearColor function, which supports dynamic updates to a frame rate of no less than 60 FPS.

[0023] Furthermore, the system also includes a data preprocessing module for filtering, interpolating, and correcting simulation data, supporting access to normal operating conditions, extreme operating conditions, and fault operating conditions.

[0024] Furthermore, the integrated scheduling module is compatible with multiple resolutions, including 1920×1080, 2560×1440 and 3840×2160, and supports human-computer interaction in global navigation mode, target navigation mode and free navigation mode.

[0025] Furthermore, the system runs in a distributed hardware environment, with computing resources including a CPU with no less than 64 cores and 64GB of memory, and graphics card resources including a GPU with at least 48GB of video memory.

[0026] Furthermore, the system employs a data visualization method, which includes the following steps:

[0027] 1) Construct a three-dimensional digital base for the test bench and generate a lightweight model through lightweight processing;

[0028] 2) Integrate multibody dynamics simulation data and power grid simulator data based on the FMI standard;

[0029] 3) Drive real-time updates of the 3D scene and use stress calculation and shading techniques to render motion, stress, and strain cloud maps;

[0030] 4) Multi-screen linkage display and interactive control are achieved through an integrated scheduling module.

[0031] Furthermore, in the stress calculation step, a parallel computing framework is used to asynchronously process multi-component data to ensure that the stress evaluation time is no more than 29ms and the rendering time is no more than 10ms.

[0032] This invention enables the construction and simulation of test benches and unit mechanistic models, combines mechanical motion data for stress and fatigue analysis, and utilizes a visualized 3D base for multi-dimensional real-time rendering and presentation. The systems run on independent computers and communicate via data interfaces, addressing the need for integrated control throughout the entire lifecycle, and achieving system integration and consolidation. Attached Figure Description

[0033] Figure 1 This is a diagram of the architecture of the present invention;

[0034] Figure 2 This is a schematic diagram of the overall structure of the test bench;

[0035] Figure 3 This is a simulation framework diagram for the model exchange mode;

[0036] Figure 4 A diagram illustrating the co-simulation framework for code export methods;

[0037] Figure 5 A diagram illustrating the co-simulation framework using coupling methods for simulation tools;

[0038] Figure 6 This is a diagram of a distributed co-simulation framework. Detailed Implementation

[0039] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the 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.

[0041] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0043] like Figure 1 , Figure 2 , Figure 3 As shown, this invention discloses a low-altitude three-dimensional virtual simulation environment data visualization system, primarily used for simulation calculations before actual experiments to verify safety and estimate lifespan loss. The system integrates functions such as multibody dynamics models, strength fatigue analysis models, three-dimensional digital base construction, real-time data-driven visualization, and integrated scheduling. It mainly includes the following components:

[0044] System Architecture: The system adopts a layered architecture (data acquisition, simulation service, visualization layer), and realizes real-time data access through UDP protocol and JSON data packets. It integrates heterogeneous models from multiple fields in combination with the FMI (Functional Mock-up Interface) standard, and supports model exchange and joint simulation mode.

[0045] Lightweight Model and 3D Base Construction: Based on CAD tools (such as SolidWorks) for forward design and combined with reverse correction technology, high-precision lightweight 3D model construction of key structures of the test bench is achieved (number of components ≥ 30), and the number of model faces does not exceed 60,000, ensuring efficient rendering.

[0046] Real-time data processing and visualization: Through stress calculation algorithms (using the Eigen library for linear algebra calculations) and vertex shading technology, the stress assessment and rendering time for the entire component is ≤40ms, and multi-color cloud maps are supported for dynamic display of motion, stress, and strain data.

[0047] Integrated scheduling and multi-screen interaction: Design an integrated scheduling module that supports single-screen switching, three-screen linkage and large-screen four-screen display, and realize the integration of accompanying simulation, evaluation analysis and visualization systems.

[0048] Data-driven mechanism: Based on multibody dynamics simulation data (such as displacement and load) and power grid simulator data (voltage, current, etc.), the three-dimensional scene is updated in real time, supporting simulation of multiple operating conditions (such as normal, extreme, and fault conditions).

[0049] The simulation system constructs and simulates the mechanism models of the test bench and the unit, performs stress and fatigue analysis based on mechanical motion data, and provides multi-dimensional real-time rendering and presentation through a visualized 3D base. The system runs on independent computers and communicates via data interfaces, integrating and consolidating systems to meet the needs of integrated control throughout the entire lifecycle.

[0050] Simulation data service: Based on the UDP protocol, a communication interface is designed to access simulation platform result data, perform data preprocessing and storage according to data characteristics, and support multi-dimensional visualization applications of simulation.

[0051] Multi-dimensional simulation visualization: Design the platform's geometric model, construct a visualization scene, connect to simulation data services, and realize multi-dimensional display of mechanical motion, component stress, and fatigue.

[0052] Simulation platform application integration: Based on multi-dimensional visualization of simulation, a display layer reuse mechanism is designed to integrate the simulation platform into applications.

[0053] Table 1: System Function List

[0054]

[0055]

[0056]

[0057] Test bench model design:

[0058] Based on industrial design models, we study lightweight model technology, construct a high-precision digital infrastructure library for all key structures of the test bench, which has the characteristics of visualization, interactivity, lightweight and precision. We design a full three-dimensional digital base for the test bench, load and analyze the digital infrastructure, and realistically simulate low-altitude three-dimensional scenes.

[0059] Mechanism modeling analysis and data integration-driven research:

[0060] The structure of the test rig was analyzed, the operating mechanism and linkage relationship of the rig were clarified, and the multibody dynamics model and stress fatigue analysis model of all key structural components were analyzed and studied. Based on the full three-dimensional digital base of the rig, the mechanism model was integrated and driven to run in real time, supporting the visualization simulation of the six-degree-of-freedom mechanical motion state of the key structure and the presentation of stress fatigue analysis.

[0061] Test Bench Mechanism Model: Based on different structural forms and power flow directions, gear transmission test benches can be divided into two types: open and closed. In an open power flow transmission test bench, the kinetic energy provided by the drive system passes through the testing system and is then converted into heat and other forms of energy by the loading system. Energy flows in one direction, so open test benches are characterized by simple structure, low cost, and high energy consumption. Closed power flow transmission test benches are based on open power flow test benches, with modifications or additions to allow power to circulate internally within the test bench. Therefore, closed test benches are characterized by low energy consumption and high economic applicability. The most common type, the closed power flow test bench, is further subdivided into mechanical power closed-loop and electric power closed-loop systems based on the power circulation principle and the components involved in the power circulation. Unlike open test benches, mechanical closed-loop test benches form a mechanical closed loop with the testing system, loading system, and auxiliary testing system. The power provided by the drive system is mainly used to compensate for energy losses caused by friction and transmission errors. The loading system generally uses hydraulic or mechanical loading methods. Therefore, mechanical power closed-loop test benches are characterized by low energy consumption, stepless loading, complex equipment, and large footprint. Electric power closed-loop test benches convert electrical energy into kinetic energy through the drive system. After passing through the testing and auxiliary testing systems, the generator, acting as the loading device, converts the kinetic energy back into electrical energy for use in the drive system or for grid connection. Therefore, electric power closed-loop test benches are characterized by high energy efficiency, dynamic loading capability, high cost, and complex electrical systems. The composition of various test benches is as follows: Figure 2 As shown.

[0062] Servo Motor Model: The main internal components of a servo motor include the rotor, stator, position sensor, bearings, and impeller. Considering the complexity of the motor structure, and in accordance with the requirements for dynamic models in the German GL2010 certification outline, the servo motor model is simplified to a rigid body model of the stator and rotor. Positioning is achieved by setting the hinge relationship between the two. Based on the actual operating principle of the motor, the relative motion degree of freedom between the rotor and stator is defined as rotation only around the x-axis. A torsional spring damping force element (FE43) is established to simulate the torque output of the servo motor. A hinge point (Marker) is set at the center point of the rotor as the power output point. After applying an excitation signal, it can simulate constant speed output or a function-varying speed output.

[0063] The servo motor and motor bracket, as well as the motor bracket and steel pad, are all connected at four points by bolts. Since the support stiffness has a significant impact on the simulation results of the dynamic response and elastic force of the system, the connection stiffness between the main components must be considered during modeling. In order to simulate the actual coupling state between the servo motor and the support structure, the bolt connection is established by the 4-point flexible support method, that is, all translational degrees of freedom are released, and the bushing force element (FE5) is used to simulate the connection state at all bolt connections.

[0064] Coupling Model: The test bench contains three flexible slat couplings connecting the servo motor, reducer, and other major components. These flexible couplings not only absorb vibration and mitigate impact, but also compensate for machining and installation errors. The coupling's damping compensates for vibration displacement and intensity in the transmission system, while its stiffness affects the system's characteristic frequency.

[0065] Since the flexibility of the coupling has a significant impact on the vibration characteristics of the transmission system, its flexibility needs to be considered when modeling the coupling dynamics. The bushing material of the plum blossom coupling is high-strength aluminum alloy AL6061, and the elastomer material is German TPU. In order to simplify the model reasonably, the coupling can be equivalent to a structure of 3 rigid bodies and 2 pairs of torsion spring damping force elements. The flexibility of the coupling is reflected by defining the stiffness of the torsion springs.

[0066] Brake Model: The brake serves as the loading device for the test bench, providing torque to simulate the load torque experienced by the reducer under actual operating conditions. The brake mainly consists of components such as an outer stator, inner stator, rotor, magnetic powder, and coils.

[0067] Considering the complex internal structure of the brake, the same modeling method as the servo motor model was used to simplify it into a shell model (outer stator) and a rotor model. Based on the aforementioned transmission principle and coupling relationship, the brake was assembled by defining the hinge relationship between the rotor center node and the shell center node, retaining only the degree of freedom of motion around the x-axis. A torque force element (FE50) was established between the center nodes of the shell and the rotor, and a user-defined expression was established to control the torque output form, accurately simulating the load characteristic curve of the magnetic powder brake. The bolt connection between the brake and the test bench was established based on the 4-point flexible support method.

[0068] Data Integration: To address the challenge of co-simulating heterogeneous models across multiple domains, the simulation community proposed the FMI (Flexible Interface Management) universal interface standard. The FMI standard encapsulates models from different domains into a unified file format, ending in .fmu, which is essentially a compressed data file. This type of compressed data file contains two types of data: XML (Extensible Markup Language) files and DLL (Dynamic Link Library) files. These two types of data files respectively contain static information and dynamic interaction information of the model units.

[0069] The FMI standard can encapsulate domain-specific models into two different methods: Model-Exchange FMU and Co-Simulation FMU

[56] . The biggest difference between the two methods is that the Model-Exchange FMU model does not come with a solver for solving the model equations when it is encapsulated, while the Co-Simulation FMU model can use its own solver to solve the model equations. The Model-Exchange FMU model and the Co-Simulation FMU model have their own advantages and disadvantages in different application scenarios and are suitable for different needs.

[0070] The model exchange method encapsulates the FMU model, including interface functions called by the integration platform, as well as various mathematical equations, component parameters, and component variables required for model simulation. All FMU models encapsulated using the model exchange method require the integration environment to provide a unified solver to solve the model equations. The advantages of this method are flexible simulation process control, faster response to external interruptions or abnormal situations during the solution process, and lower resource overhead for co-simulation because the integration environment provides only one unified solver. However, when dealing with model elements encapsulated by different tools representing the equations, using only a single unified solver cannot guarantee performance and accuracy; the results may even be completely different. The interaction between the FMU and the simulation environment under the model exchange method is as follows: Figure 3 As shown.

[0071] Compared to the FMU model in the model exchange method, the FMU model in the co-simulation method can use its built-in solver. The interface provided by the FMU model is only used to process the instructions at the start of the solution, the signals during the solution completion process, the initialized internal parameters and input variables, and to obtain the output variables. Co-simulation in this mode does not require a unified solver from the simulation environment; only a master algorithm from the main simulation environment is needed to control the information exchange between sub-models and the synchronization of all solvers from the simulation tools. The advantage of the co-simulation method is that the simulation environment can directly encapsulate the dedicated solver with the FMU model elements, effectively guaranteeing the performance and accuracy of the simulation. However, the disadvantage of the co-simulation model is that the model element simulation is executed step-by-step; the model elements cannot process any information other than the model solver during the simulation steps, including external interruptions or state transitions. The FMI standard co-simulation method can be divided into three different working modes according to different use cases.

[0072] Mode 1: Co-simulation method using code export

[0073] like Figure 4 As shown, the FMU model, encapsulated through code export, is freed from the constraints of domain-specific simulation tools. The FMU model includes model equations and solvers, and its use does not require the application license or rights certificate restrictions of the original exporting tool. Multiple FMU models can be used in a unified simulation environment to complete the simulation and solution of complex system equipment using the same process.

[0074] Mode 2: Co-simulation method with tool coupling

[0075] like Figure 5 As shown, the FMU model encapsulated through tool coupling, like the FMU model encapsulated in Mode 1, includes model equations and solvers. However, the FMU model encapsulated through tool coupling requires binding to the license of the original exporting tool and cannot escape the constraints of the domain-specific simulation tools. The FMU model is only used to implement the interface encapsulation and data interaction functions for co-simulation; the solution of the model equations is actually performed within each slave simulation tool. The main control software is responsible for data exchange and flow between the various slave simulation tools at fixed time points in an independent process. Each slave simulation tool needs to occupy a separate process to solve the model equations, and the solution processes of different slave simulation tools do not interfere with each other.

[0076] Mode 3: Distributed Co-simulation Method

[0077] like Figure 6As shown, the distributed co-simulation method and the tool-coupled co-simulation method are largely similar. The difference is that the tool-coupled method is based on a single computing platform, where multiple simulation tools start their own processes to solve the model equations. In contrast, the distributed method distributes different simulation tools across different computing platforms. Data interaction between different computing platforms relies not only on the external interface of the FMU model but also on the communication layer between the node server and the node client to transmit data.

[0078] Full 3D digital visualization:

[0079] Around the business system, a ground test bench simulation and display system is built, constructing multi-dimensional model data of test bench related elements to form an immersive visualization scene, accessing test bench related test data, driving the movement of the model in the virtual scene to complete the virtual-real synchronization of the equipment, providing a global perception of the test bench related layout, displaying the test process in multiple dimensions, supporting the drawing of structural 3D models in the form of multi-color cloud maps, and intuitively displaying the safety performance and operating status of each structure.

[0080] By accessing JSON test data packets via the UDP data protocol, the simulation data of key structural components of the test bench is included. Data fusion analysis is performed for upper-layer applications. Through model data matching and correlation, the synchronization of the visualization scene model state is driven, realizing multi-dimensional data presentation of structural motion, stress state, and fatigue.

[0081] Integrated scheduling application integration: To meet the needs of integrated centralized control throughout the entire life cycle, an integrated scheduling module is designed. The system layer integrates accompanying simulation, evaluation and analysis and visualization systems. Based on hardware resource configuration, it can realize single-screen scheduling switching, three-screen linkage and large screen four-screen display, realizing integrated application control presentation of the test simulation platform.

[0082] A single screen allows for human-computer interaction, enabling the push of visualization system, pre-simulation, and process simulation details interfaces.

[0083] The three screens work together to present the simulation process, displaying the multibody dynamics simulation model, fatigue and stress analysis system, and visualization system from left to right, according to the simulation flow.

[0084] Multibody dynamics simulation model:

[0085] In actual operation, the simulation step size was set to 1ms and the simulation duration to 1min. A single working condition was calculated, and the simulation production data was 15M.

[0086] Increasing the duration to 20 minutes generates 300MB of data, and the simulation time for 3000 operating conditions is [data missing].

[0087] 20min * 3000 = 60000min = 1000h = 41.6 working days = 124 days, generating 3000 * 300M = 0.85T of data; therefore, the annual production data volume is 0.85T * 365 / 124 days = 2.5T;

[0088] Storage resources: 2.5TB / year;

[0089] Computing resources: 64-core CPU; 64GB RAM;

[0090] Fatigue and stress assessment system:

[0091] Stress state analysis of key structures can be performed within 30ms, generating 500M of data per single working condition and 32T of data per year.

[0092] Storage resources: 32TB / year;

[0093] Computing resources: 64-core CPU; 64GB RAM;

[0094] Graphics card resources: 48GB;

[0095] Visual simulation system:

[0096] Simulation results are rendered in real time based on multibody dynamics models and fatigue stress analysis data.

[0097] Storage resources: 4G;

[0098] Computing resources: 64-core CPU; 64GB RAM;

[0099] Graphics card resources: 48G*2;

[0100] System performance description:

[0101]

[0102]

[0103] Indicator 1: Stress assessment and rendering time for all components ≤ 40ms

[0104] Stress Calculation: To ensure stress assessment time for all components is within milliseconds, it is necessary to rationally mesh the components and employ an efficient linear algebra library to achieve rapid data calculation. Testing showed that the longest stress calculation time was 29ms.

[0105] The 3D model is formed by meshes, which are composed of numerous triangles. Therefore, mesh rendering is essentially the rendering of triangles. Three points define a face. In the view engine, different vertex orders result in different graphics (different normals). Vertex shading method: Based on the mesh rendering method, real-time rendering of the model structure is achieved, while also incorporating stress calculation data for color rendering. The specific method is as follows:

[0106] In the `UProceduralMeshComponent` function `CreateMeshSection_LinearColor`, there's a variable `constTArray&VertexColors`. This array stores the color corresponding to each vertex. You only need to assign different colors to the three points that form the triangle.

[0107] vertexColors.Add(FLinearColor::Blue); / / Assign blue color to the first vertex

[0108] vertexColors.Add(FLinearColor::Green); / / Assign green color to the second vertex

[0109] vertexColors.Add(FLinearColor::Red); / / Assign red color to the third vertex

[0110] MeshComponent->CreateMeshSection_LinearColor(0,vertices,triangles,normals,uvs,vertexColors,tangents,true);

[0111] Indicator 2: Number of detailed modeling components for low-altitude 3D scenes ≥ 30

[0112] By using forward design and reverse correction, a 3D model is constructed for low-altitude 3D scenes to ensure that the model's accuracy meets the requirements. At the same time, the model group components are decomposed using a mechanism model data-driven approach to ensure that the number of models constructed is 33.

[0113] Forward Model Design: Forward model design tools are generally CAD tools, including SolidWorks, Catia, Creo, UG, etc. The construction of 3D models for equipment can be based on CAD 2D design drawings. This embodiment uses SolidWorks as an example to illustrate the forward model design process.

[0114] SolidWorks is a feature-based parametric 3D solid modeling system. By considering the overall structure of the design goals before starting the design and then developing a good design roadmap, the system's functionality can be effectively utilized, the model creation speed can be accelerated, and design time can be saved.

[0115] In SolidWorks, the approach to modeling product models with slightly complex structures and shapes is to decompose the entire product into multiple features. A complete and accurate product model is then gradually obtained through Boolean operations between these features. Often, the most important or largest part of the entire product is considered the basic feature, and its shape is created first. Other parts are treated as additional features, and like building blocks, Boolean operations such as adding, removing, and finding intersections are performed on the basic features to ultimately obtain the complete product model. Finally, smaller features are added, such as chamfers, fillets, and holes, resulting in the final accurate and complete product model. The creation of each feature basically follows the same steps.

[0116] Creating a 3D solid feature is a process of transforming a 2D feature into a 3D one. The first step in generating a 3D solid feature is to draw the feature's outline, and sometimes trajectory lines, at a suitable location (on the initial sketch plane). The most crucial aspect of this is generating a suitable initial sketch plane. The purpose of the sketch plane is to inform the system of the specific position of the feature outline to be drawn in 3D space, preparing for the further generation of the 3D solid feature. SolidWorks provides comprehensive definition functions, allowing you to use the three coordinate planes in the 3D coordinate system as initial sketch planes. In subsequent design steps, typically, a sketch plane can be defined for each added feature. This sketch plane not only includes the three coordinate planes mentioned earlier, but also spatial planes obtained by offsetting, rotating, or tangenting from these coordinate planes; alternatively, you can select a flat surface of an already generated 3D solid feature, or a spatial plane obtained by offsetting, rotating, or tangenting from it. These comprehensive definition functions fully meet our needs for defining sketch planes when designing 3D solid features.

[0117] After defining the accurate initial sketch plane, you can draw the feature projection outline on this sketch plane. You can use various commands provided by SolidWorks for drawing planar graphics (lines, circles, arcs, polylines, rectangles, points, etc.) to draw them. Then, constrain the drawn sketch outline. By adding sufficient constraints (including dimensional and geometric constraints) to the feature outline, you can obtain an outline that meets the actual needs. In some cases, certain features also require the generation of the path required by that feature.

[0118] After completing the 2D sketch, you can generate various corresponding 3D solid features by calling the modeling commands provided by SolidWorks. Below is the SolidWorks modeling process:

[0119] (1) Analyze entities

[0120] The goal of this step is to identify the features that make up the design target, which feature should be the basic feature (i.e., the first feature to be created), and then to determine the order in which the various features that make up the design target are created. The order in which features are created has a significant impact on modeling efficiency. Generally speaking, auxiliary features such as holes and fillets should be processed last.

[0121] (2) Creating basic features

[0122] 1) Sketching. The plane used to draw the two-dimensional outline of features is called the sketch plane. 2D commands such as Line, Polyline, and Circle can be used to draw sketch outlines.

[0123] 2) Apply constraints to the sketch. Common constraint types include geometric constraints and dimensional constraints. Geometric constraints guarantee the geometric shape of the drawing; dimensional constraints can adjust the size of the part. Generally, the total number of constraints in a sketch equals the number of dimensional constraints plus the number of geometric constraints. Geometric constraints should be used more frequently, such as collinearity, concentricity, tangency, and perpendicularity.

[0124] 3) Create basic features. Use the stretch, revolve, sweep, and other methods provided by SolidWorks to generate a 3D solid from the fully constrained sketch, which is the basic feature of the part.

[0125] (3) Add new features

[0126] Adding new features is similar to creating basic features, but with the following differences: If the new feature to be created is not a hole, chamfer, fillet, or array, a sketch plane needs to be defined. This is because the sketch plane is a temporary two-dimensional working coordinate plane; sketching can only be performed after the sketch plane is selected. In addition to creating constraints on the new feature's outline sketch, constraints must also be applied between the sketch and existing features. Therefore, the order in which features are created should be carefully considered when adding new features. Constraining the sketch allows for parametric design of the newly created feature, i.e., adding constraints between existing features and the sketch, establishing connections between features, and ensuring that these connections remain unchanged when a feature is modified.

[0127] (4) Generate two-dimensional engineering drawings

[0128] In SolidWorks, once a 3D solid model is completed, you can use the 3D to 2D conversion function provided by SolidWorks to automatically generate a 2D projection drawing by selecting the view and projection direction, and automatically annotate some dimensions that have been defined in the model.

[0129] Model reverse engineering:

[0130] (1) Three-dimensional model design method

[0131] Currently, there are three main types of forward modeling methods for 3D models: 3D software modeling, instrument and equipment measurement modeling, and modeling based on images or videos.

[0132] 1) 3D software modeling

[0133] 3D software modeling primarily involves constructing 3D models by performing a series of geometric operations and Boolean operations on basic geometric elements. 3D software can be used for geometric modeling, behavioral modeling, physical modeling, object property modeling, and model segmentation, among other things.

[0134] 2) Measurement modeling of instruments and equipment

[0135] The most commonly used instruments and equipment for measurement and modeling include 3D scanners, cameras, and laser scanners. Among them, 3D scanners can convert real-world three-dimensional color information into digital signals that can be directly processed by computers, thus digitizing real objects.

[0136] 3) Modeling based on images or videos

[0137] Image-Based Modeling and Rendering (IBMR) technology can capture the realism of photographs in the most natural way. It works by recovering the three-dimensional geometry of a scene from a two-dimensional image.

[0138] This invention provides a simulation data visualization system for pre-test simulation in low-altitude three-dimensional scenarios. Before conducting full-scale unit tests, it performs simulation calculations on the test bench and the unit to verify the safety of key systems in the low-altitude three-dimensional scenario and predict the lifespan loss of key components after the test. The system develops a simulation data visualization system that, combined with the simulation test requirements of the test bench, analyzes, studies, and integrates multibody dynamics models and strength and fatigue analysis models, providing simulation data for design conditions and supporting the simulation of the mechanism model in the low-altitude three-dimensional scenario. A fully three-dimensional digital base for the low-altitude three-dimensional scenario is designed and developed, encompassing multi-dimensional model data of relevant elements, forming a three-dimensional visualization scene. This scene provides a global view of the test bench's motors, mechanics, hydraulics, electrical systems, power grid simulator, and surrounding service facilities, displaying the process in multiple dimensions. It supports multi-color cloud map display of the real-time synchronous dynamic display of the motion, stress, and strain of key structural components in the low-altitude three-dimensional scenario, intuitively displaying the safety performance, fatigue life loss, and operating status of each structure. This invention provides the following:

[0139] Digital infrastructure construction for the test bench: Based on the refined design model, the model is lightweighted and a high-precision digital infrastructure library for the key structures of the test bench is constructed. It has the characteristics of visualization, interactivity, lightweight and precision, forming a full three-dimensional digital base for the test bench. The digital infrastructure is loaded and analyzed to simulate low-altitude three-dimensional scenes in multiple dimensions.

[0140] Test bench mechanism model data interface: Based on the test bench's composition structure, operation mechanism, and component linkage relationship, it provides data interface capabilities for multibody dynamics models and stress fatigue analysis models of all key structural components in a low-altitude 3D scene. It can integrate and drive the mechanism model operation based on the test bench's full 3D digital base, supporting the visualization simulation of the six-degree-of-freedom mechanical motion state of key structures and the presentation of stress fatigue analysis data.

[0141] Full 3D Digital Visualization: The design incorporates a full 3D digital base for the test rig, encompassing multi-dimensional model data of relevant elements. It provides a global view of the rig's structure, subsystems, and surrounding service facilities, offering a multi-dimensional display of the testing process. Data fusion analysis is performed for upper-level applications. Through model data matching and correlation, the visualization scene model status is synchronized, enabling multi-dimensional data presentation of key component motion, stress, and strain. This provides a clear view of the safety performance, fatigue life loss, and operational status of each structure. The test process is displayed in a multi-dimensional manner, supporting multi-color cloud maps to display real-time synchronous dynamic display of the motion, stress, and strain of key structural components in low-altitude 3D scenes, intuitively showing the safety performance, fatigue life loss, and operational status of each structure.

[0142] Integrated scheduling application integration: To meet the needs of integrated centralized control throughout the entire life cycle, an integrated scheduling module is designed. The system layer integrates accompanying simulation, evaluation and analysis and visualization systems. Based on hardware resource configuration, it can realize single-screen scheduling switching, three-screen linkage and large screen four-screen display, realizing integrated application control presentation of the test simulation platform.

[0143] Any process or method described in the flowcharts of this invention or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, which can be implemented in any computer-readable medium for use by an instruction execution system, apparatus, or device. The computer-readable medium can be any medium containing a program for storage, communication, propagation, or transmission for use by an execution system, apparatus, or device, including read-only memory, magnetic disks, or optical disks.

[0144] In the description of this specification, references to terms such as "embodiment," "example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, those skilled in the art can combine or combine the different embodiments or examples described in this specification and the features therein without causing contradiction.

[0145] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Therefore, any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention should fall within the protection scope of the present invention.

Claims

1. A low-altitude three-dimensional virtual simulation environment data visualization system, characterized in that, include: The test bench digital infrastructure module is used to perform lightweight model processing based on the refined design model and construct a high-precision three-dimensional digital base for the key structure of the test bench. The three-dimensional digital base covers multi-dimensional model data of the test bench's motor, mechanical, hydraulic, electrical and power grid simulators. The number of model faces does not exceed 60,000 and the number of components is not less than 30. The mechanism model data interface module encapsulates multibody dynamics models and stress fatigue analysis models based on the FMI standard, supports model exchange and co-simulation mode, and accesses JSON format simulation data packets via UDP protocol to achieve data integration of heterogeneous models from multiple fields; The full 3D visualization module is used to load the 3D digital base and, based on stress calculation algorithms and vertex shading technology, drive the motion, stress and strain data of key structures to be rendered in real time in the form of multi-color cloud maps. The stress assessment and rendering time of the entire component is no more than 40ms. The integrated scheduling module combines accompanying simulation, evaluation analysis, and visualization systems, supporting single-screen scheduling switching, three-screen linkage, and large-screen four-screen display for integrated application control of the experimental simulation platform.

2. The system according to claim 1, characterized in that, The digital infrastructure module of the test bench uses CAD tools for forward model design and combines a 3D scanner for reverse correction. The lightweight model processing includes automatic mesh generation and PBR material mapping, with a texture resolution of no less than 512×512.

3. The system according to claim 1, characterized in that, The mechanism model data interface module supports three co-simulation modes of the FMI standard: code export mode, tool coupling mode, and distributed mode. The distributed mode achieves cross-platform data interaction through the node server and client communication layer.

4. The system according to claim 1, characterized in that, The stress calculation algorithm of the full 3D visualization module is implemented based on the Eigen library and includes the following steps: 1) Divide the component mesh into multiple triangular facets; 2) Calculate the stress tensor of each node using linear algebra and generate stress distribution data based on the Mises stress formula; 3) Using vertex shading technology, stress data is mapped to color values ​​and drawn on the surface of the 3D model in real time.

5. The system according to claim 4, characterized in that, The vertex shading technique includes: In UProceduralMeshComponent, assign color values ​​to the three vertices of each triangle. Color interpolation rendering is implemented through the CreateMeshSection_LinearColor function, which supports dynamic updates to a frame rate of no less than 60 FPS.

6. The system according to claim 1, characterized in that, The system also includes a data preprocessing module for filtering, interpolating, and correcting simulation data, supporting access to normal operating conditions, extreme operating conditions, and fault operating conditions.

7. The system according to claim 1, characterized in that, The integrated scheduling module is compatible with multiple resolutions, including 1920×1080, 2560×1440 and 3840×2160, and supports human-computer interaction in global navigation mode, target navigation mode and free navigation mode.

8. The system according to claim 1, characterized in that, The system runs in a distributed hardware environment, with computing resources including a CPU with no less than 64 cores, 64GB of memory, and graphics card resources including a GPU with at least 48GB of video memory.

9. The system according to claim 1, characterized in that, The system employs a data visualization method, which includes the following steps: 1) Construct a three-dimensional digital base for the test bench and generate a lightweight model through lightweight processing; 2) Integrate multibody dynamics simulation data and power grid simulator data based on the FMI standard; 3) Drive real-time updates of the 3D scene and use stress calculation and shading techniques to render motion, stress, and strain cloud maps; 4) Multi-screen linkage display and interactive control are achieved through an integrated scheduling module.

10. The system according to claim 9, characterized in that, In the stress calculation step, a parallel computing framework is used to asynchronously process data from multiple components, ensuring that the stress evaluation time is no more than 29ms and the rendering time is no more than 10ms.

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