Ship production line welding operation training system based on digital twin model

Abstract

The application provides a ship production line welding operation training system based on a digital twin model, comprising a model establishing module, a data display view module, a safety training module, a fault simulation training module and a statistical analysis module; the model establishing module is used for establishing a virtual digital twin model based on a ship welding production line, collecting multi-source data through a data interface, and mapping and updating the virtual digital twin model in real time by using the multi-source data; the data display view module comprises a production management view unit and an operation view unit; the safety training module comprises an operation demonstration unit, a process demonstration unit and an interactive training unit; the fault simulation training module comprises a fault handling simulation training unit and a fault handling process demonstration unit; and the statistical analysis module is used for statistically analyzing multi-source data and outputting optimization suggestions. The system provided by the application is helpful to improve the welding production line training efficiency.

Description

Technical Field

[0001] This invention relates to the field of ship production line technology, and in particular to a ship production line welding operation training system based on a digital twin model. Background Technology

[0002] Ship welding is a core process in shipbuilding, and its operational standardization and troubleshooting capabilities directly determine welding quality and production line efficiency. Currently, the ship welding industry generally faces the following pain points in training and production management: 1. Traditional operation training is inefficient and risky: Ship welding equipment has a complex structure and high operational threshold. Traditional training relies on a "master-apprentice" model, requiring new employees to observe and learn on the actual production line. This not only consumes production equipment resources but also poses safety risks such as high temperatures, sparks, and gas leaks during welding. Novice errors can easily lead to burns, explosions, and other accidents. Furthermore, training content depends on the individual experience of the master, resulting in inconsistent transmission of operational points and generally long onboarding periods for new employees. 2. Lack of effective means to cultivate troubleshooting capabilities: Ship welding production lines experience diverse types of malfunctions. Traditional troubleshooting training relies solely on written manuals or case studies, lacking practical scenario support. New employees often feel helpless when faced with actual malfunctions, leading to troubleshooting times exceeding one hour and severely impacting production line continuity. 3. Production monitoring data is scattered and not intuitive: The equipment status, production data and fault records of the existing welding production line are scattered in different systems. Production managers need to switch between multiple platforms to view the data, making it difficult to quickly establish the "data-scenario" relationship. Anomaly identification is delayed and decision-making efficiency is low. Summary of the Invention

[0003] In view of this, the purpose of this invention is to provide a ship production line welding operation training system based on a digital twin model, which is suitable for new employee operation training and emergency drills in ship assembly and mid-assembly welding production lines. At the same time, it can assist production managers in realizing production line status monitoring and production optimization decisions.

[0004] This invention provides a training system for welding operations on a ship production line based on a digital twin model, including: a model building module, a data display view module, a safety training module, a fault simulation training module, and a statistical analysis module;

[0005] The model building module is used to build a virtual digital twin model based on the ship welding production line. It collects multi-source data through the data interface and uses the multi-source data to map and update the virtual digital twin model in real time.

[0006] The data display view module includes a production management view unit and an operation view unit. The production management view unit is used to display a global dashboard view, equipment status heat map view, and fault tracking view for production management personnel, while the operation view unit is used to display a workstation operation panel view for operators.

[0007] The safety training module includes an operation demonstration unit, a process demonstration unit, and an interactive training unit. The operation demonstration unit is used to demonstrate the core operations and key points of each welding process in the form of 3D animation. The process demonstration unit is used to demonstrate the overall process of welding in the form of 3D animation. The interactive training unit is used to train operators to complete the core operations of each welding process in a virtual digital twin model.

[0008] The fault simulation training module includes a fault handling simulation training unit and a fault handling process demonstration unit. The fault handling simulation training unit is equipped with an interactive screen, allowing operators to conduct fault simulation training through fault scenarios. The fault handling process demonstration unit is used to demonstrate the fault handling process in the form of 3D animation after the operators have completed the training.

[0009] The statistical analysis module is used to perform statistical analysis on multi-source data and output optimization suggestions.

[0010] Furthermore, establishing a virtual digital twin model based on the ship welding production line includes: using Unity3D software to create a virtual digital twin model based on the CAD drawings and equipment parameters of the ship welding production line. The virtual digital twin model can reproduce the production line layout, equipment appearance and operation logic of the ship welding production line in a 1:1 ratio.

[0011] Furthermore, multi-source data includes real-time operational data, fault data, and production data;

[0012] Data collection through multiple sources includes: collecting real-time operational data by connecting to welding equipment via the device sensor interface; collecting production data by connecting to the shipbuilding manufacturing execution system via the MES interface; and collecting fault data by connecting to the fault recording system via the fault recording system interface.

[0013] Furthermore, when connecting to the welding equipment via the device sensor interface, the OPC UA protocol is used for data acquisition, with a data acquisition frequency of ≥1 time / second.

[0014] Furthermore, using multi-source data to update the virtual digital twin model in real time includes: mapping action logic to the virtual digital twin model in real time, enabling the virtual digital twin model to display the action logic, and synchronously displaying and updating real-time operating parameters near the virtual digital twin model during the display of the action logic.

[0015] Furthermore, the global dashboard view can display key production line indicators. When a key production line indicator is lower than a preset threshold, the key production line indicator is automatically highlighted in red, and a trend curve of the key production line indicator for the past 7 days is automatically generated.

[0016] The equipment status thermal view can display the load rate of welding equipment and mark the load rate with different colors according to the value of the load rate. When the load rate of welding equipment exceeds a preset threshold, the welding equipment is marked as a bottleneck equipment. The equipment status thermal view can also display the production cycle data of the welding process.

[0017] The fault tracking view can display fault data for unresolved faults sorted by fault level, as well as an explanation of the impact on material delivery schedules associated with unresolved faults.

[0018] The workstation operation panel view can display the current workstation's production plan data, real-time operating parameters, the number of completed welding processes, the pass rate of each welding process, and the production plan achievement rate.

[0019] Furthermore, the interactive training unit is equipped with an interactive screen, allowing operators to drag virtual welding equipment and related components on the virtual digital twin model to complete the core operations of each welding process.

[0020] Furthermore, for the fault handling simulation training unit, operators can select either the training mode or the assessment mode to conduct fault simulation training.

[0021] When the operator selects the training mode, the operator can repeatedly practice how to handle the fault in any fault scenario. During the practice, the fault handling simulation unit can generate and display real-time operation prompts based on the solutions and fault handling time in the fault data.

[0022] When the operator selects the assessment mode, the fault handling simulation unit can randomly generate a fault scenario. Each fault scenario corresponds to a fault handling assessment task with an assessment time.

[0023] Furthermore, after operators complete the fault simulation training, they can use the fault handling simulation training unit to query the handling solutions for relevant fault cases.

[0024] Furthermore, the fault handling simulation unit can record operation information and generate an assessment report based on the operation information. The operation information includes, but is not limited to, the faulty equipment number, the completeness of the handling steps, the actual handling time, and the correctness of the operation.

[0025] The beneficial effects of this invention are as follows: The system provided in this application can realize the real-time acquisition and virtual mapping of real-time operation data, production data, and fault data of ship welding production lines. It can complete new employee operation training and fault emergency drills in the form of 3D animation, while providing production managers with an intuitive production line visualization monitoring view. This solves the problems of low efficiency in traditional welding training, difficulty in fault response, and scattered data monitoring, and has the dual value of training empowerment and production optimization.

[0026] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained in accordance with the structures particularly pointed out in the description, claims and drawings.

[0027] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0028] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of a ship production line welding operation training system based on a digital twin model, provided as an embodiment of the present invention. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions 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, not all embodiments. 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.

[0031] Example 1

[0032] To facilitate understanding of this embodiment, in conjunction with Figure 1 This invention provides a detailed description of a ship production line welding operation training system based on a digital twin model, as disclosed in this embodiment. The system includes: a model building module, a data display module, a safety training module, a fault simulation training module, and a statistical analysis module.

[0033] The following is a detailed description of the above modules:

[0034] The model building module is used to build a virtual digital twin model based on the ship welding production line. It collects multi-source data through a data interface and uses the multi-source data to map and update the virtual digital twin model in real time.

[0035] The multi-source data includes real-time operational data, fault data, and production data.

[0036] Real-time operating data includes welding parameters, equipment position, and status signals. Welding parameters include welding current, welding voltage, and welding speed; status signals include power on / off / fault.

[0037] Fault data includes, but is not limited to, fault occurrence timestamp, fault equipment number, fault location, fault type, fault handler, fault handling duration, fault level, solution, and fault details. Fault details include temporary fault handling experience manually entered into the fault record system by the fault handler. In this embodiment, fault types include, but are not limited to, welding torch blockage, robot positioning deviation (e.g., positioning deviation value > 0.5mm), insufficient shielding gas pressure (e.g., shielding gas pressure < 0.3MPa), welding torch continuous use exceeding the time limit without cleaning (e.g., usage time exceeding 8 hours), and welding current continuously exceeding the limit (e.g., welding current exceeding 450A for at least 5 minutes). Fault levels include Level 1 faults and Level 2 faults, with Level 1 faults being more urgent than Level 2 faults.

[0038] Production data includes production planning, overall equipment efficiency (OEE), the number of welds completed, the pass rate of each weld, production cycle time, work-in-process inventory, material delivery progress, and production plan achievement rate. Furthermore, the welds include tack welding, full welds, and flaw detection; the material delivery progress refers to the delivery progress of welding wire / shielding gas.

[0039] Based on this, establishing a virtual digital twin model for the ship welding production line includes: using Unity3D software to create a virtual digital twin model based on the CAD drawings and equipment parameters of the ship welding production line. This virtual digital twin model can reproduce the production line layout, equipment appearance, and motion logic of the ship welding production line in a 1:1 ratio, ensuring consistency in size and motion between the virtual digital twin model and its corresponding physical entity. Furthermore, the production line layout includes welding robots, welding stations, and conveyor lines; the equipment appearance includes the welding gun structure of the welding robot and the roller conveyor design of the conveyor line; and the motion logic includes the welding actions of the welding robot, the start / stop / speed adjustment actions of the conveyor line, and the clamping actions of the tooling fixtures at the welding stations.

[0040] Data is collected from multiple sources via data interfaces, including: real-time operational data collected by connecting to welding equipment via device sensor interfaces; production data collected by connecting to the shipbuilding manufacturing execution system via MES interfaces; and fault data collected by connecting to the fault recording system via fault recording system interfaces. The welding equipment includes welding robots, conveyor lines, and tooling fixtures at the welding stations.

[0041] As a preferred implementation, when connecting to the welding equipment via the device sensor interface, the OPC UA protocol is used for data acquisition, with a data acquisition frequency of ≥1 time / second.

[0042] Real-time updates of the virtual digital twin model using multi-source data include: mapping action logic to the virtual digital twin model in real time, enabling the virtual digital twin model to display the action logic. During the display of the action logic, real-time operating parameters are simultaneously displayed and updated near the virtual digital twin model. For example, when a welding robot on the production line is powered on, the virtual digital twin model can display green and simulate the welding robot's actions, while the real-time welding current of 320A is simultaneously displayed and updated near the virtual digital twin model. In this embodiment, the mapping delay is ≤100ms during the real-time mapping of action logic to the virtual digital twin model, ensuring that the actual production line and the virtual digital twin model remain synchronized.

[0043] The data display view module includes a production management view unit and an operation view unit. The production management view unit is used to display a global dashboard view, equipment status heat map view, and fault tracking view for production management personnel, while the operation view unit is used to display a workstation operation panel view for operators.

[0044] The global dashboard view displays key production line indicators. When these indicators fall below preset thresholds, they are automatically highlighted in red, and a trend curve for the past 7 days is automatically generated. In this embodiment, key production line indicators include Outstanding Efficiency (OEE), work-in-process inventory, production plan achievement rate, fault handling time, and fault level. For example, when OEE and fault handling time exceed a first threshold (OEE < 90% and fault handling time > 1 hour), the overall equipment efficiency and fault handling time are automatically highlighted in red.

[0045] The equipment status thermal view can display the load rate of welding equipment and mark the load rate with different colors according to the value of the load rate. When the load rate of welding equipment exceeds a preset threshold, the welding equipment is marked as a bottleneck device. The equipment status thermal view can also display the production cycle data of the welding process. In this embodiment, the equipment status thermal view can mark the load rate with different colors according to the value of the welding equipment load rate as follows: when the load rate is less than or equal to 60%, the load rate is marked as green; when the load rate is 61% to 80%, the load rate is marked as yellow; and when the load rate is greater than 80%, the load rate is marked as red. For example, when the preset threshold is 92%, and the load rate of a certain welding equipment is 92%, the load rate of the welding equipment is marked as red, and the welding equipment is marked as a bottleneck device.

[0046] The fault tracking view displays fault data for unprocessed faults sorted by fault level, along with an explanation of the impact on material delivery schedules associated with these unprocessed faults.

[0047] The workstation operation panel view can display the current workstation's production plan data, real-time operating parameters, the number of completed welding processes, the pass rate of each welding process, and the production plan achievement rate. For example, the current workstation's production plan data is displayed as: "Fully welded workpiece number W20240601, 8 pieces remaining".

[0048] The safety training module includes an operation demonstration unit, a process demonstration unit, and an interactive training unit. The operation demonstration unit is used to demonstrate the core operations and key points of each welding process in the form of 3D animation. The process demonstration unit is used to demonstrate the overall process of welding in the form of 3D animation. The interactive training unit is used to train operators to complete the core operations of each welding process in a virtual digital twin model.

[0049] The core operations of each welding process in the operation demonstration unit include welding torch clamping, welding parameter setting, weld trajectory calibration, and workpiece loading and unloading. For example, when the core operation is welding torch installation, the operation demonstration unit can demonstrate the specific steps of welding torch installation, including: "Opening the welding torch protective cover" → "Inserting the welding wire" → "Adjusting the extension length to 3-5mm" → "Closing the protective cover" → "Testing the wire feeding smoothness"; it can also simultaneously demonstrate key operational points, namely, demonstrating the corresponding welding parameters for steel plates of different thicknesses, including demonstrating a welding current of 280A for 6mm steel plates and 350A for 12mm steel plates; and it can simultaneously demonstrate the virtual weld effect (a smooth weld when welding parameters are correct, and undercut or incomplete penetration when welding errors occur).

[0050] For the process demonstration unit, in this embodiment, the overall welding process includes the following steps: "Warehouse" → "Positioning Welding Station" → "Full Welding Station" → "Flaw Detection Station" → "Finished Product Warehouse". For "Warehouse" → "Positioning Welding Station", "Positioning Welding Station" → "Full Welding Station", and "Full Welding Station" → "Flaw Detection Station", each step is marked with time requirements and a first connection logic. The first connection logic includes preconditions and flow rules; each step must meet its preconditions before executing the flow rules between that step and the next. For "Flaw Detection Station" → "Finished Product Warehouse", time requirements and a second connection logic are marked. The second connection logic includes a qualified flow procedure, a non-qualified handling procedure, and a traceability synchronization procedure.

[0051] For example, for the "warehouse" → "positioning welding station" process, the time requirement for the "warehouse" stage is as follows: after the workpiece leaves the warehouse, it must be delivered to the positioning welding station and ready for loading within 2 hours. The prerequisite for the "warehouse" stage is: "the warehouse needs to count the number of workpieces according to the production plan data and mark the workpiece information (workpiece number, workpiece specifications, welding process requirements) on the workpiece. This prerequisite ensures that the workpiece has no external damage and the workpiece size deviation meets the preset standard." The flow rule between the "warehouse" stage and the next stage "positioning welding station" is as follows: after the workpiece is delivered to the positioning welding station, the operator needs to verify that the workpiece information is consistent with the production plan data and confirm that the tooling fixture is in normal condition before starting the positioning welding operation in the "positioning welding stage".

[0052] For the transition from "Positioning Welding Station" to "Full Welding Station," the time requirement for the "Positioning Welding Station" step is as follows: After the positioning welding operation is completed, the workpiece must be transferred to the full welding station within 30 minutes (to avoid workpiece positioning deviation). The prerequisite for the "Positioning Welding Station" step is that the positioning welding process must complete a preset number of positioning welds (usually no less than 4 according to workpiece specifications, and the weld strength must meet the standards). After the operator's self-inspection (e.g., checking that the welds are not detached or have obvious deviation) is passed, the workpiece can be transferred. The transfer rules between the "Positioning Welding Station" and the next step, "Full Welding Station," are as follows: The workpiece that has passed the positioning welding must be accompanied by a process transfer card. The operator at the full welding station must verify the recorded information on the process transfer card (positioning welding operator, completion time, self-inspection results) before the full welding operation can be started at the "Full Welding Station."

[0053] For the transition from "full welding station" to "flaw detection station", the time requirement for the "full welding station" is as follows: after the full welding operation is completed, the weld must be transferred to the flaw detection station within 1 hour (to avoid secondary defects after the weld cools down, which would affect the accuracy of the inspection). The prerequisites for the "full welding station" are: the full welding process must complete the welding of all welds, and the welding parameters must meet the preset process requirements. After the operator's self-inspection (e.g., whether the weld has the following appearance defects: no obvious undercut, incomplete penetration, porosity, cracks) is qualified, the weld can be transferred. The transfer rules between the "full welding station" and the next "flaw detection station" are as follows: the workpiece that has passed the full welding must be accompanied by a self-inspection record. After the operator at the flaw detection station checks the self-inspection record, the weld is inspected according to the preset inspection methods (e.g., ultrasonic testing, radiographic testing) to obtain the flaw detection results.

[0054] For the "flaw detection station" → "finished product warehouse" process, the time requirements for the "flaw detection station" are as follows: After the flaw detection is completed, qualified workpieces must be transferred to the finished product warehouse within 2 hours; unqualified workpieces must be immediately transferred to the rework station, and can only be transferred to the finished product warehouse after rework is completed and re-inspection is qualified. The qualified transfer procedure for the "flaw detection station" is as follows: The flaw detection result shows that the weld quality meets the preset standard (e.g., weld qualification rate ≥ 97%), and a weld quality inspection qualification report is issued. The workpiece can only enter the finished product warehouse with the weld quality inspection qualification report attached. The finished product warehouse management personnel complete the warehouse entry registration after verifying the report information.

[0055] The non-conformance handling procedure at the "flaw detection station" is as follows: If the flaw detection result shows that the weld has unconforming defects (such as cracks or severe incomplete penetration), a weld quality non-conformance notice is issued, and the workpiece is transferred to the rework station. A rework plan (such as repair welding or grinding) is formulated according to the defect type. After the rework is completed, flaw detection is carried out again until the flaw detection result shows that the weld quality meets the preset standard. If the weld still shows unconforming defects after rework, the workpiece is processed according to the scrap process and must not be transferred to the finished product warehouse. The traceability and synchronization procedure at the "flaw detection station" is as follows: All records of the circulation process (flaw detection station operators, flaw detection station operation time, flaw detection results) must be entered into the shipbuilding execution system simultaneously to ensure that the weld quality is traceable.

[0056] The interactive training unit is equipped with an interactive screen, allowing operators to drag and drop virtual welding equipment and related components onto a virtual digital twin model to complete the core operations of each welding process. In this embodiment, the interactive training unit can determine whether the operator's operation is correct. If the operation is incorrect, the operation demonstration unit will re-demonstrate the core operations of each welding process until the operator's operation is qualified.

[0057] The fault simulation training module includes a fault handling simulation training unit and a fault handling process demonstration unit. The fault handling simulation training unit is equipped with an interactive screen, allowing operators to conduct fault simulation training through fault scenarios. The fault handling process demonstration unit is used to demonstrate the fault handling process in the form of 3D animation after the operators have completed the training.

[0058] The fault scenarios are simulated based on the fault types in the fault data. For example, when the fault type is welding torch blockage, the corresponding fault scenario is: the welding sparks become smaller and the wire feeding is interrupted; when the fault type is robot positioning deviation, the corresponding fault scenario is: the virtual weld deviates from the standard trajectory, and the virtual weld attachment is marked with a deviation value; when the fault type is insufficient shielding gas pressure, the corresponding fault scenario is: the shielding gas pressure value is displayed in real time, and a message is displayed indicating that the shielding gas pressure is insufficient.

[0059] Based on this, for the fault handling simulation training unit, operators can select the training mode or the assessment mode to conduct fault simulation training.

[0060] When operators select the training mode, they can repeatedly practice handling faults in any fault scenario. During this practice, the fault handling simulation unit can generate and display real-time operation prompts based on the solutions and handling times in the fault data. For example, when the fault type is insufficient protective gas pressure, operators can perform operations such as closing the gas cylinder valve, checking for leaks, and replacing seals on the virtual digital twin model. At the same time, the fault handling simulation unit can display "Standard handling time ≤ 8 minutes, please speed up the operation."

[0061] As an optional implementation, after completing fault simulation training, operators can query the handling solutions for relevant fault cases through the fault handling simulation training unit. For example, when the fault type is welding torch blockage, operators can query "welding torch blockage fault record and optimal handling solution on March 15, 2024" through the fault handling simulation training unit.

[0062] When the operator selects the assessment mode, the fault handling simulation unit can randomly generate a fault scenario. Each fault scenario corresponds to a fault handling assessment task with an assessment time. The operator needs to complete the fault handling assessment task within the assessment time.

[0063] In this process, as an optional implementation, the fault handling simulation unit can record operation information and generate an assessment report based on the operation information. The operation information includes, but is not limited to, the faulty equipment number, the completeness of the handling steps, the actual handling time, and the correctness of the operation. For example, the assessment report is in the form of: "Fault type: welding torch blockage; Actual handling time: 8 minutes (standard time 5 minutes, overtime 3 minutes); Correctness of operation: Step 3 failed to turn off the equipment power, deduct 20 points; Areas for optimization: Refer to the solution in the fault data: 'Quick power-off operation specification'."

[0064] For the fault handling simulation demonstration unit, after the operator selects the training mode or assessment mode to complete the fault simulation training, the fault handling simulation training unit can demonstrate the fault handling process in the form of 3D animation. For example, when the fault type is welding torch blockage, the fault handling process is as follows: turn off the equipment power → disassemble the welding torch → clean the welding slag with special tools → check the wire feed tube → reinstall the welding torch → adjust the parameters → test weld.

[0065] The statistical analysis module is used to perform statistical analysis on multi-source data and output optimization suggestions.

[0066] The statistical analysis module can perform statistical analysis on real-time operating data, fault data, and production data, and output optimization suggestions for process parameters, equipment maintenance, and production line processes.

[0067] For example, after analyzing the real-time operating data, the statistical analysis module finds that the weld pass rate is 98% when the welding current is 310~330A, and then generates an optimization suggestion for the process parameters: "Recommended optimal welding current range: 310~330A".

[0068] After analyzing the fault data, the statistical analysis module found that the failure probability of the welding torch increased after 180 hours of use, and then generated an optimization suggestion for equipment maintenance: "Replace the welding torch after 150 hours of use".

[0069] After analyzing production data (such as production cycle data), the statistical analysis module finds that the welding equipment at a certain positioning welding station is a bottleneck device, and then generates an optimization suggestion for the production line process: "Add 1 positioning welding station".

[0070] Based on the above, the beneficial effects of the ship production line welding operation training system based on a digital twin model provided in this embodiment after 30 days of continuous operation are as follows:

[0071] 1. Training effectiveness: The onboarding period for new employees was shortened from 4 months to 1.5 months, and the operational qualification rate increased from 75% to 95%;

[0072] 2. Troubleshooting: The troubleshooting time for common faults has been reduced from 60 minutes to 18 minutes;

[0073] 3. Production indicators: OEE increased from 85% to 92%, and the pass rate of welding process increased from 92% to 97%.

[0074] It should be noted that, in this document, 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. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0075] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A training system for welding operations on a ship production line based on a digital twin model, characterized in that, include: The module includes: model building module, data display view module, safety training module, fault simulation training module, and statistical analysis module. The model building module is used to build a virtual digital twin model based on the ship welding production line. It collects multi-source data through the data interface and uses the multi-source data to map and update the virtual digital twin model in real time. The data display view module includes a production management view unit and an operation view unit. The production management view unit is used to display a global dashboard view, equipment status heat map view, and fault tracking view for production management personnel, while the operation view unit is used to display a workstation operation panel view for operators. The safety training module includes an operation demonstration unit, a process demonstration unit, and an interactive training unit. The operation demonstration unit is used to demonstrate the core operations and key points of each welding process in the form of 3D animation. The process demonstration unit is used to demonstrate the overall process of welding in the form of 3D animation. The interactive training unit is used to train operators to complete the core operations of each welding process in a virtual digital twin model. The fault simulation training module includes a fault handling simulation training unit and a fault handling process demonstration unit. The fault handling simulation training unit is equipped with an interactive screen, allowing operators to conduct fault simulation training through fault scenarios. The fault handling process demonstration unit is used to demonstrate the fault handling process in the form of 3D animation after the operators have completed the training. The statistical analysis module is used to perform statistical analysis on multi-source data and output optimization suggestions.

2. The ship production line welding operation training system based on a digital twin model according to claim 1, characterized in that, The creation of a virtual digital twin model based on a ship welding production line includes: using Unity3D software to create a virtual digital twin model based on the CAD drawings and equipment parameters of the ship welding production line. The virtual digital twin model can reproduce the production line layout, equipment appearance and operation logic of the ship welding production line in a 1:1 ratio.

3. The ship production line welding operation training system based on a digital twin model according to claim 1, characterized in that, Multi-source data includes real-time operational data, fault data, and production data; Data collection through multiple sources includes: collecting real-time operational data by connecting to welding equipment via the device sensor interface; collecting production data by connecting to the shipbuilding manufacturing execution system via the MES interface; and collecting fault data by connecting to the fault recording system via the fault recording system interface.

4. A ship production line welding operation training system based on a digital twin model according to claim 3, characterized in that, When connecting to welding equipment via the device sensor interface, data acquisition is performed using the OPC UA protocol, with a data acquisition frequency of ≥1 time / second.

5. A ship production line welding operation training system based on a digital twin model according to claim 1, characterized in that, Real-time updates of the virtual digital twin model using multi-source data include: mapping action logic to the virtual digital twin model in real time, enabling the virtual digital twin model to display the action logic, and synchronously displaying and updating real-time operating parameters near the virtual digital twin model during the display of the action logic.

6. A ship production line welding operation training system based on a digital twin model according to claim 1, characterized in that, The global dashboard view can display key production line indicators. When a key production line indicator is lower than a preset threshold, the key production line indicator is automatically highlighted in red, and a trend curve of the key production line indicator for the past 7 days is automatically generated. The equipment status thermal view can display the load rate of welding equipment and mark the load rate with different colors according to the value of the load rate. When the load rate of welding equipment exceeds a preset threshold, the welding equipment is marked as a bottleneck equipment. The equipment status thermal view can also display the production cycle data of the welding process. The fault tracking view can display fault data for unresolved faults sorted by fault level, as well as an explanation of the impact on material delivery schedules associated with unresolved faults. The workstation operation panel view can display the current workstation's production plan data, real-time operating parameters, the number of completed welding processes, the pass rate of each welding process, and the production plan achievement rate.

7. A ship production line welding operation training system based on a digital twin model according to claim 1, characterized in that, The interactive training unit is equipped with an interactive screen, which allows operators to drag virtual welding equipment and related components on the virtual digital twin model to complete the core operations of each welding process.

8. A ship production line welding operation training system based on a digital twin model according to claim 1, characterized in that, For the fault handling simulation training unit, operators can select either the training mode or the assessment mode to conduct fault simulation training. When the operator selects the training mode, the operator can repeatedly practice how to handle the fault in any fault scenario. During the practice, the fault handling simulation unit can generate and display real-time operation prompts based on the solutions and fault handling time in the fault data. When the operator selects the assessment mode, the fault handling simulation unit can randomly generate a fault scenario. Each fault scenario corresponds to a fault handling assessment task with an assessment time.

9. A ship production line welding operation training system based on a digital twin model according to claim 7, characterized in that, After operators complete the fault simulation training, they can use the fault handling simulation training unit to query the handling solutions for relevant fault cases.

10. A ship production line welding operation training system based on a digital twin model according to claim 7, characterized in that, The fault handling simulation unit can record operation information and generate an assessment report based on the operation information. The operation information includes, but is not limited to, the faulty equipment number, the completeness of the handling steps, the actual handling time, and the correctness of the operation.

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