A monitoring method and a monitoring system for a physical production system
By using digital twin technology to acquire and map operational status data in real time within the steel rolling production system and generate dynamic images, the problem of difficulty in intuitively monitoring the production system in existing technologies is solved, and efficient production system monitoring is achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHOUGANG JINGTANG IRON & STEEL CO LTD
- Filing Date
- 2026-04-08
- Publication Date
- 2026-07-14
AI Technical Summary
In existing technologies, steel rolling production systems have a wide variety of equipment and complex logic, making it difficult to achieve intuitive monitoring of the production system through configuration software or SCADA systems, which affects production efficiency and quality.
Digital twin technology is used to acquire real-time operational status data of the production system and map it onto a three-dimensional digital model to generate dynamic images synchronized with the production process, thereby enabling visual monitoring of the production system.
It improves the intuitiveness and monitoring efficiency of the production system's operating status, enabling real-time display of equipment status and fault information, guiding fault handling, and enhancing the monitoring effect of the production system.
Smart Images
Figure CN122386802A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of production system technology, and in particular to a monitoring method and monitoring system for physical production systems. Background Technology
[0002] In related technologies, the steel rolling production process often includes multiple processes such as QR code scanning, visual positioning, robot transfer, laser cutting, and CNC milling. Correspondingly, the steel rolling production system includes equipment corresponding to multiple processes. Such production systems have a wide variety of equipment, complex logic, and high requirements for coordination. During the production process, it is necessary to effectively monitor multiple devices in the production line to ensure production efficiency and quality.
[0003] In related technologies, production systems are typically monitored using configuration software or Supervisory Control and Data Acquisition (SCADA) systems. However, this monitoring method can only statically display a two-dimensional image of the production system on a screen, making it difficult to intuitively monitor the complex operating status of individual devices. Therefore, how to effectively improve the intuitiveness of the production system monitoring process has become an urgent technical problem to be solved. Summary of the Invention
[0004] The summary section of this application introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. The summary section of this application is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.
[0005] The monitoring method and system for physical production systems disclosed in this application acquire real-time operational status data (including location information) of the physical production system during operation, and synchronously map the data onto a three-dimensional digital model based on digital twin technology to generate dynamic images. By displaying these dynamic images, monitoring personnel can intuitively monitor the operation of the production system, thereby improving the intuitiveness of the production system's operational status display.
[0006] In a first aspect, embodiments of this application provide a monitoring method for a physical production system, comprising: acquiring a three-dimensional digital model corresponding to the physical production system; acquiring first operating status data of the physical production system in real time during the operation of the physical production system; wherein the first operating status data includes the location information of the physical production system; synchronously mapping the first operating status data to the three-dimensional digital model based on digital twin technology to generate a dynamic image that is synchronized in real time with the operation process of the physical production system; and outputting the dynamic image for visual monitoring of the operation process of the physical production system.
[0007] In some implementations, based on digital twin technology, the first operating state data is synchronously mapped to a three-dimensional digital model to generate a dynamic image that is synchronized with the operation of the physical production system in real time. This includes: establishing a static image corresponding to the physical production system based on the three-dimensional digital model; and synchronously mapping the location information to the virtual location information of the static image based on digital twin technology to generate a dynamic image that is synchronized with the operation of the physical production system in real time.
[0008] In some implementations, the monitoring method further includes: in response to a fault information indicating that a target component is in a fault state, determining the cause of the fault in the target component based on second operating state data; determining fault handling guidance information corresponding to the cause of the fault; and displaying the fault handling guidance information in a dynamic image based on the position corresponding to the target component.
[0009] In some implementations, the monitoring method further includes: acquiring production data of the physical production system within a target historical time period; generating a production status corresponding to the target historical time period based on the production data; and displaying the production status in a dynamic image in response to a selection instruction for the target historical time period.
[0010] Secondly, this application also provides a monitoring device for a physical production system, comprising: an acquisition unit for acquiring a three-dimensional digital model corresponding to the physical production system; and for acquiring first operating status data of the physical production system in real time during the operation of the physical production system; wherein the first operating status data includes the location information of the physical production system; a mapping unit for synchronously mapping the first operating status data to the three-dimensional digital model based on digital twin technology to generate a dynamic image that is synchronized with the operation process of the physical production system in real time; and an output unit for outputting the dynamic image for visual monitoring of the operation process of the physical production system.
[0011] In some implementations, the mapping unit is specifically used to: establish a static image corresponding to the physical production system based on the three-dimensional digital model; and based on digital twin technology, synchronously map the location information to the virtual location information of the static image to generate a dynamic image that is synchronized in real time with the operation of the physical production system.
[0012] In some embodiments, the acquisition unit is further configured to: acquire second operating status data of the target component in the physical production system in real time; the monitoring system further includes a determination unit, configured to determine fault information of the target component based on the second operating status data; the output unit is further configured to, in response to the fault information indicating that the target component is in a fault state, mark the fault state at the position corresponding to the target component in the dynamic image.
[0013] In some embodiments, the determining unit is further configured to: in response to a fault information indicating that the target component is in a fault state, determine the cause of the fault of the target component based on the second operating state data; determine fault handling guidance information corresponding to the cause of the fault; the output unit is further configured to display the fault handling guidance information in the dynamic image based on the position corresponding to the target component.
[0014] In some implementations, the acquisition unit is further configured to: acquire production data of the physical production system within a target historical time period; the determination unit is further configured to generate a production status corresponding to the target historical time period based on the production data; and the output unit is further configured to display the production status in a dynamic image in response to a selection instruction for the target historical time period.
[0015] Thirdly, this application also provides an electronic device, including: a memory and a processor, the processor being configured to implement the steps of the monitoring method for a physical production system of the first aspect when executing a computer program stored in the memory.
[0016] Fourthly, this application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps of the monitoring method for a physical production system of the first aspect.
[0017] Fifthly, this application also provides a computer program product, including a computer program or computer-executable instructions, which, when executed by a processor, implement the steps of the monitoring method for a physical production system provided in the embodiments of this application.
[0018] In summary, the production system monitoring method and system of this application can be based on digital twin technology, such as Unity3D, MATLAB / Simulink, or Three.js software. By acquiring real-time operational status data (including location information) of the physical production system during its operation, and synchronously mapping this data onto a three-dimensional digital model using digital twin technology, the generated dynamic image can maintain real-time synchronization with the physical production system's operation. By displaying this dynamic image, monitoring personnel can intuitively monitor the production system's operation. Compared to related technologies that only monitor the production system's operational status based on static two-dimensional images, this method further improves the intuitiveness of the production system's operational status display, thereby effectively enhancing the monitoring efficiency of the production system. Attached Figure Description
[0019] Figure 1 A flowchart illustrating a monitoring method for a physical production system provided in an embodiment of this application;
[0020] Figure 2 A structural block diagram of a monitoring device for a physical production system provided in an embodiment of this application; Figure 3 A structural block diagram of a production line provided in an embodiment of this application; Figure 4 This application provides a schematic diagram of the structure of a production line according to an embodiment of the present application. Figure 5 This is a structural block diagram of an electronic device provided in an embodiment of this application. Detailed Implementation
[0021] The terms used in the specification, claims, and drawings of this application, such as "first," "second," "third," "fourth," etc. (if any), are used to distinguish similar objects and not to describe a specific order or sequence. Therefore, it is to be understood that these terms can be used interchangeably where appropriate, allowing the described embodiments to be used in different orders, unless specifically required by the illustrations or description. Furthermore, the terms "is" and "has," and any variations thereof, are intended to cover, non-exclusively, all possible constituent elements. For example, a process, method, system, product, or apparatus comprising several steps or units is not necessarily limited to the steps or units explicitly listed, but may also include other steps or units not explicitly listed, or steps or units inherent to the process, method, product, or apparatus.
[0022] In this application, a "module" or "unit" refers to a computer program or part of a computer program that has a specific function and works in conjunction with other related parts to achieve a predetermined goal. These modules or units can be implemented by software, hardware (e.g., processing circuitry or memory), or a combination of both. One or more processors or memories can implement one or more modules or units. Furthermore, each module or unit can also be part of a larger module or unit.
[0023] The technical solutions of this application will be described in detail below with reference to the accompanying drawings of the embodiments. It should be noted that the described embodiments are only a part of this application, and not all embodiments. In the following description, the "some embodiments" mentioned are only a subset of all possible embodiments, which may be the same or different subsets, and different embodiments can be combined with each other without conflict.
[0024] Figure 1 This is a flowchart illustrating a monitoring method for a physical production system provided in an embodiment of this application. For example, see [link to example]. Figure 1 The monitoring method for a physical production system provided in this application embodiment may include the following steps 101 to 104: Step 101: Obtain the three-dimensional digital model corresponding to the physical production system.
[0025] In some examples, a physical production system can refer to a production line used to produce products. Taking steel rolling as an example, the steel rolling production process often includes multiple processes such as QR code scanning, visual positioning, robot transfer, laser cutting, and CNC milling. Correspondingly, the steel rolling production line includes equipment corresponding to multiple processes. Such production lines have a wide variety of equipment, complex logic, and high requirements for coordination. During the production process, it is necessary to effectively monitor multiple devices in the production line to ensure production efficiency and quality.
[0026] The three-dimensional digital model corresponding to the physical production system can be a three-dimensional digital model established based on the shape and structural parameters of multiple production devices in the physical production system. For example, the three-dimensional digital model of the physical production system can be established using 3D modeling software. That is, the shape and structural parameters of the multiple production devices in the physical production system are input into the 3D modeling software, which then establishes the three-dimensional digital model of the physical production system based on these parameters. For example, 3D modeling software such as 3ds Max and SolidWorks can be used.
[0027] By implementing step 101, a three-dimensional digital model of the physical production system is obtained. Then, based on the three-dimensional digital model, a real-time synchronized dynamic image of the physical production system during operation can be generated, which is to prepare for generating a real-time synchronized dynamic image of the physical production system during operation.
[0028] Step 102: During the operation of the physical production system, acquire the first operating status data of the physical production system in real time.
[0029] The first operational status data includes the location information of the physical production system.
[0030] In some examples, when the physical production system is in operation, it is possible to acquire the first operating status data of the physical production system. Specifically, the first operating status data of the physical production system may include the real-time location information of each component of the physical production system during operation.
[0031] For example, a Programmable Logic Controller (PLC) of the physical production system can be used to acquire the initial operational status data of the physical production system during operation. It is understood that the PLC can control the operation of various production devices within the physical production system. Specifically, the PLC can send control commands to the physical production system, and the physical production system responds to the received control commands by executing actions corresponding to the commands, that is, operating according to the operational parameters indicated by the control commands. Simultaneously, the PLC can also collect the operational parameters of the physical production system in real time during operation. These operational parameters include the initial operational status data of the physical production system. This initial operational status data includes the physical production system's location information, and may also include motion status data (such as speed and acceleration), equipment status parameters (such as process parameters such as temperature, pressure, and current), equipment operating modes (such as automatic / manual, running / standby), and real-time alarm or fault signals. This initial operational status data, collected and aggregated by the PLC, is transmitted in real time to the monitoring system via industrial network protocols, thus providing an accurate, continuous, and multi-dimensional data foundation for subsequently constructing a digital twin dynamic image synchronized with the physical system.
[0032] By implementing step 102, the first operating status data of the physical production system is acquired in real time during the operation of the physical production system, that is, the position information of each component during the operation of the physical production system. In this way, the three-dimensional digital model of the physical production system obtained in step 101 can be combined to generate dynamic images of the physical production system during operation, so that the generated dynamic images can be synchronized with the operation of the physical production system in real time.
[0033] Step 103: Based on digital twin technology, the first operating state data is synchronously mapped to a three-dimensional digital model to generate a dynamic image that is synchronized in real time with the physical production system operation process.
[0034] In some examples, after acquiring the 3D digital model and initial operational status data of the physical production system, digital twin technology can be used to synchronously map the initial operational status data into the 3D digital model. This means mapping the positional information of each component of the physical production system into the 3D digital model. It is understandable that since the positional information of each component of the physical production system is acquired in real time during the system's operation, this positional information can be mapped into the 3D data model in real time. This allows each component in the 3D data model to adjust its position based on the real-time acquired positional information, thus generating a dynamic image of the physical production system during operation.
[0035] For example, image processing software based on digital twin technology can be used to synchronously map the first operating state data of the physical production system into a three-dimensional digital model of the physical production system. For instance, image processing software based on digital twin technology, such as Unity3D, MATLAB / Simulink, or Three.js, can be used to synchronously map the first operating state data, thereby generating dynamic images of the physical production system during operation.
[0036] By implementing step 103, based on digital twin technology, the first operating state data of the physical production system is synchronously mapped to the three-dimensional digital model of the physical production system, thereby generating dynamic images of the physical production system during operation. The generated dynamic images can be synchronized with the operation of the physical production system in real time, and monitoring personnel can intuitively monitor the operation of the production system by observing the dynamic images.
[0037] Step 104: Output dynamic images for visual monitoring of the operation of the physical production system.
[0038] In some examples, after generating dynamic images of the physical production system in operation, the dynamic images can be output, that is, displayed. For example, the output of dynamic images can be a real-time display of the generated dynamic images on a monitor, so that monitoring personnel can observe the dynamic images displayed on the monitor, thereby realizing real-time monitoring of the operation of the physical production system.
[0039] By implementing step 104, dynamic images of the physical production system during operation can be displayed for monitoring personnel to observe. Furthermore, since the generated dynamic images are synchronized in real-time with the operation of the physical production system, displaying these dynamic images allows monitoring personnel to intuitively monitor the production system's operation.
[0040] In summary, the production system monitoring method and system of this application can be based on digital twin technology, such as Unity3D software based on digital twin technology. By acquiring the operating status data (including location information) of the physical production system in real time during operation, and synchronously mapping the data to a three-dimensional digital model based on digital twin technology, the generated dynamic image can be kept in real time synchronized with the operation of the physical production system. By displaying this dynamic image, monitoring personnel can intuitively monitor the operation of the production system. Compared with the related technologies that can only monitor the operating status of the production system based on static two-dimensional images of the production system, this method can further improve the intuitiveness of the production system's operating status display, thereby effectively improving the monitoring efficiency of the production system.
[0041] In some embodiments, step 103 may include: establishing a static image corresponding to the physical production system based on the three-dimensional digital model; and synchronously mapping the location information to the virtual location information of the static image based on digital twin technology to generate a dynamic image that is synchronized in real time with the operation of the physical production system.
[0042] In some examples, after acquiring a 3D digital model of a physical production system, image processing software based on digital twin technology can first create a static image corresponding to the physical production system based on the 3D digital model. The image processing software can then perform image processing such as modeling and rendering on the 3D digital model of the physical production system, thereby converting it into a displayable static image.
[0043] Then, based on digital twin technology, the first operating state data is synchronously mapped to the three-dimensional digital model, that is, the position information of each component of the physical production system is synchronously mapped to the virtual position information of the static image, thereby generating dynamic images of the physical production system during operation.
[0044] Understandably, digital twin technology enables bidirectional mapping and real-time interaction between the physical and virtual worlds. In some examples, based on digital twin technology, the initial operational state data collected from a physical production system can be transmitted to a static image of the physical production system. This means synchronously mapping the positional information of each component of the physical production system to the virtual positional information of the static image. Then, a high-fidelity virtual model corresponding to the operation of the physical production system is constructed in virtual space. The state of the virtual model can change in real time according to the changes in the physical production system, thus generating a dynamic image corresponding to the operation of the physical production system.
[0045] Through the implementation of the above embodiments, after obtaining the three-dimensional digital model of the physical production system, a static image of the physical production system is established based on the three-dimensional digital model. Then, through digital twin technology, the first operating status data of the physical production system is synchronously mapped to the virtual location information in the static image, thereby converting the static image into a dynamic image synchronized with the operating process of the physical production system. By displaying this dynamic image, monitoring personnel can intuitively monitor the operating process of the production system. Compared with the related technologies that can only monitor the operating status of the production system based on the static two-dimensional image of the production system, this method can further improve the intuitiveness of the display of the operating status of the production system, thereby effectively improving the monitoring efficiency of the monitoring personnel.
[0046] In some embodiments, the monitoring method for a physical production system further includes: acquiring second operating status data of a target component in the physical production system in real time; determining fault information of the target component based on the second operating status data; and, in response to the fault information indicating that the target component is in a fault state, marking the location corresponding to the target component in a dynamic image to indicate the fault state.
[0047] In some examples, during the operation of the physical production system, it is also possible to acquire second operational status data of the target component within the physical production system. For example, the second operational status data may include the target component's position data, travel distance data, collision data during movement, and operational parameters controlling the target component's operation.
[0048] For example, image processing software based on digital twin technology can interact with a programmable logic controller (PLC) in a physical production system via a WebSocket server. The PLC can transmit data to the WebSocket server via an industrial protocol, which may include data transmission protocols such as OPC UA and Modbus.
[0049] Then, based on the second operating status data, it is determined whether there is any fault information in the target component during operation. For example, based on the target component's position data, it can be determined whether the target component has moved to the required target position. If the position data indicates that the target component has not moved to the required target position, then the current fault information of the target component indicates that the target component is in a fault state. Alternatively, if collision data of the target component is obtained during its movement, it indicates that the target component has collided with other components during its movement, and in this case, the current fault information of the target component can also be determined to indicate that the target component is in a fault state.
[0050] When a fault message indicating that a target component is in a faulty state is detected, the corresponding location of the target component can be marked in the dynamic image in response to this fault state. For example, when a fault message indicating that a target component is in a faulty state is detected, firstly, the dynamic image can be switched to a screen that displays the target component. Then, the single target component in the screen is displayed in a highlighted or flashing manner to mark the faulty target component. In this way, monitoring personnel can intuitively observe the location of the faulty target component.
[0051] Through the implementation of the above embodiments, based on the second operating status data of the target component, it is determined whether there is fault information in the target component during operation. In this way, when the fault information of the target component indicates that the target component is in a fault state, by marking the corresponding position of the target component in the dynamic image, the monitoring personnel can intuitively observe the location of the target component that caused the fault, thereby improving the efficiency of fault handling of the target component.
[0052] In some embodiments, the monitoring method further includes: in response to a fault information indicating that a target component is in a fault state, determining the cause of the fault in the target component based on second operating state data; determining fault handling guidance information corresponding to the cause of the fault; and displaying the fault handling guidance information in a dynamic image based on the position corresponding to the target component.
[0053] In some examples, when the fault information of the target component indicates that the target component is in a faulty state, in response to this faulty state, the cause of the target component's fault can be determined based on the target component's second operating state data. For example, if collision data of the target component is acquired during its movement, it indicates that the target component has collided with other components during its movement. In other words, the cause of the target component's fault at this time is a collision with other components. Furthermore, the cause of the collision can be analyzed based on the second operating state data; for example, the target component's movement distance may be too large, leading to a collision with other components.
[0054] Then, the fault handling guidance information corresponding to the cause of the fault can be determined. For example, if the cause of the collision between the target component and other components is excessive travel, the corresponding fault handling guidance information can be set to adjust the control parameters of the target component to reduce its travel, thereby preventing the target component from colliding with other components due to excessive travel.
[0055] Once the cause of the target component's failure and the corresponding troubleshooting guidance information have been determined, this guidance information can be displayed in the dynamic image. Specifically, the display of the guidance information can be based on the location of the target component. By displaying this guidance information, the troubleshooting of the target component can be guided, thereby improving the efficiency of fault handling.
[0056] Through the implementation of the above embodiments, when it is determined that the fault information of the target component indicates that the target component is in a fault state, the cause of the fault of the target component is determined according to the second operating state data of the target component. Then, based on the cause of the fault, fault handling guidance information corresponding to the cause of the fault is determined. Then, the fault handling guidance information is displayed in the dynamic image based on the position of the target component to guide relevant personnel to handle the fault of the target component, effectively improving the fault handling efficiency of the target component.
[0057] In some embodiments, the monitoring method further includes: acquiring production data of the physical production system within a target historical time period; generating a production status corresponding to the target historical time period based on the production data; and displaying the production status in a dynamic image in response to a selection instruction for the target historical time period.
[0058] In some examples, during the operation of the physical production system, production data of the physical production system within a target historical time period can also be acquired. For example, the operation data of the physical production system within the target historical time period can be acquired by a programmable logic controller that controls the physical production system, and then the production data of the physical production system within the target historical time period can be determined based on the operation data.
[0059] Then, based on the production data, a production status corresponding to the target historical time period can be generated. For example, the programmable logic controller (PLC) can transmit the production data to a MySQL database. The production data can be aggregated and calculated from the MySQL database to generate the production status of the physical production system. The MySQL database then sends the production status to image processing software, which can then display the production status in a dynamic image. At this point, monitoring personnel can select a target historical time period, i.e., generate a selection command for that target historical time period. In response to the selection command for the target historical time period, the production status corresponding to that target historical time period can be displayed in the dynamic image.
[0060] Through the implementation of the above embodiments, based on the production data of the physical generation system within the target historical time period, a production status corresponding to the target historical time period is generated. When a selection instruction for the target historical time period is received, the production status corresponding to the target historical time period can be displayed in the dynamic image, thereby enabling monitoring personnel to intuitively monitor the production status of the physical production system, thereby further improving the monitoring efficiency of the monitoring personnel on the production system.
[0061] Furthermore, as an implementation of the foregoing method embodiments, this application also provides a monitoring device for a physical production system, used to implement the foregoing method embodiments. This device embodiment corresponds to the foregoing method embodiments. For ease of reading, this monitoring device embodiment for a physical production system will not repeat the details of the foregoing method embodiments one by one, but it should be understood that the device in this application embodiment can correspondingly implement all the contents of the foregoing method embodiments. Figure 2 A flowchart illustrating a monitoring device for a physical production system provided in this application embodiment is shown below. Figure 2The monitoring device 20 for the physical production system includes: an acquisition unit 201, used to acquire a three-dimensional digital model corresponding to the physical production system; and to acquire first operating status data of the physical production system in real time during the operation of the physical production system; wherein the first operating status data includes the location information of the physical production system; a mapping unit 202, used to synchronously map the first operating status data to the three-dimensional digital model based on digital twin technology, so as to generate a dynamic image that is synchronized with the operation process of the physical production system in real time; and an output unit 203, used to output the dynamic image for visual monitoring of the operation process of the physical production system.
[0062] In some embodiments, the mapping unit 202 is specifically used to: establish a static image corresponding to the physical production system based on the three-dimensional digital model; and based on digital twin technology, synchronously map the location information to the virtual location information of the static image to generate a dynamic image that is synchronized with the operation process of the physical production system in real time.
[0063] In some embodiments, the acquisition unit 201 is further configured to: acquire second operating status data of the target component in the physical production system in real time; the monitoring system further includes a determination unit, configured to determine fault information of the target component based on the second operating status data; the output unit 203 is further configured to, in response to the fault information indicating that the target component is in a fault state, mark the position corresponding to the target component in the dynamic image as a fault state.
[0064] In some embodiments, the determining unit is further configured to: in response to a fault information indicating that the target component is in a fault state, determine the cause of the fault of the target component based on the second operating state data; determine fault handling guidance information corresponding to the cause of the fault; the output unit 203 is further configured to display the fault handling guidance information in the dynamic image based on the position corresponding to the target component.
[0065] In some embodiments, the acquisition unit 201 is further configured to: acquire production data of the physical production system within a target historical time period; the determination unit is further configured to generate a production status corresponding to the target historical time period based on the production data; and the output unit 203 is further configured to display the production status in a dynamic image in response to a selection instruction for the target historical time period.
[0066] In some examples, this application provides a production line. Figure 3 A structural block diagram of a production line provided in this application embodiment is shown below. Figure 3 The production line includes an equipment layer and a monitoring layer. The monitoring layer can monitor the operation of the equipment layer through the monitoring method of the physical production system as described in any of the above embodiments.
[0067] Specifically, taking a steel rolling production line as an example, the equipment layer can include laser cutting equipment, robots, CNC milling machines, intelligent handling robots, stretching machines, and other equipment. The monitoring layer can include a data layer, a model layer, a functional layer, and a presentation layer. The data layer can acquire equipment operating status data, control status data, and motion status data of each piece of equipment through the programmable logic controller (PLC) of the production equipment. The model layer can generate dynamic images of the equipment's operation process based on the equipment's static model, dynamic model, drive data, and motion parameters. The functional layer can monitor the equipment's operating status and analyze the causes of component failures, determining fault handling guidance information based on the causes. The presentation layer can display dynamic images to allow monitoring personnel to monitor the equipment's operation. It can also display corresponding fault handling guidance information when equipment malfunctions, guiding relevant personnel to repair the equipment.
[0068] In some examples, Figure 4 A schematic diagram of a production line provided in an embodiment of this application is shown below. Figure 4 The monitoring layer can include image processing software based on digital twin technology, such as Unity3D. This software can generate and display dynamic images of the device layer during operation based on the dynamic and static models, driving data, and motion parameters of each device. Data exchange between the image processing software and the programmable logic controller (PLC) at the device layer can be achieved through a WebSocket server. In some examples, the PLC can transmit data to the WebSocket server via industrial protocols, such as OPCUA and Modbus.
[0069] The monitoring layer may specifically include a MySQL database. This database monitors the operational status of the equipment and analyzes the causes of component failures, determining troubleshooting guidance information based on these causes. In some examples, the MySQL database and image processing software can interact via an HTTPS / JSON server. The HTTPS / JSON server provides a RESTful API to handle HTTP requests from the image processing software. Upon receiving relevant data from the image processing software, it can aggregate, calculate, and return structured production management information from the MySQL database, such as equipment production status and troubleshooting guidance information. This data is transmitted in JSON format, offering good readability and cross-platform compatibility.
[0070] This application also provides a computer-readable storage medium storing computer-executable instructions or computer programs that, when executed by a processor, will cause the processor to perform any step of the monitoring method for a physical production system provided in this application.
[0071] In some embodiments, the computer-readable storage medium may be a random access memory (RAM), a read-only memory (ROM), flash memory, a magnetic surface memory, an optical disc, or a compact disc read-only memory (CD-ROM); or it may be a variety of devices that include one or any combination of the above-mentioned memories.
[0072] In some embodiments, computer-executable instructions may take the form of programs, software, software modules, scripts, or code, written in any form of programming language (including compiled or interpreted languages, or declarative or procedural languages), and may be deployed in any form, including as stand-alone programs or as modules, components, subroutines, or other units suitable for use in a computing environment.
[0073] In some embodiments, computer-executable instructions may, but do not necessarily, correspond to files in a file system, and may be stored as part of a file that holds other programs or data, for example, in one or more scripts in a HyperText Markup Language (HTML) document, in a single file dedicated to the program in question, or in multiple co-located files (e.g., files that store one or more modules, subroutines, or code sections).
[0074] In some embodiments, computer-executable instructions may be deployed to execute on an electronic device, or on multiple electronic devices located at one location, or on multiple electronic devices distributed across multiple locations and interconnected via a communication network.
[0075] Figure 5 A structural block diagram of an electronic device provided in an embodiment of this application is shown below. Figure 5 This application also provides an electronic device 30, including a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor. When the processor 320 executes the computer program 311, it implements any of the steps of the above-described monitoring method for a physical production system.
[0076] This application also provides a computer program product comprising a computer program or computer-executable instructions stored in a computer-readable storage medium. A processor of an electronic device reads the computer program or computer-executable instructions from the computer-readable storage medium and executes the computer program or computer-executable instructions, causing the electronic device to perform any step of the monitoring method for a physical production system described above.
[0077] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications 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 this application.
Claims
1. A monitoring method for a physical production system, characterized in that, include: Obtain multiple three-dimensional digital models corresponding to the physical production system; During the operation of the physical production system, the first operating status data of the physical production system is acquired in real time; wherein, the first operating status data includes the location information of the physical production system; Based on digital twin technology, the first operating status data is synchronously mapped to the three-dimensional digital model to generate a dynamic image that is synchronized in real time with the operation process of the physical production system. The dynamic images are output for visual monitoring of the operation of the physical production system.
2. The monitoring method according to claim 1, characterized in that, The method of synchronously mapping the first operational status data onto the three-dimensional digital model based on digital twin technology to generate a dynamic image that is synchronized in real time with the operation of the physical production system includes: Based on the three-dimensional digital model, a static image corresponding to the physical production system is created; Based on digital twin technology, the location information is synchronously mapped to the virtual location information of the static image to generate a dynamic image that is synchronized in real time with the operation of the physical production system.
3. The monitoring method according to claim 1, characterized in that, Also includes: Real-time acquisition of the second operating status data of the target component in the physical production system; Based on the second operating status data, the fault information of the target component is determined; In response to the fault information indicating that the target component is in a fault state, the fault state is marked at the position corresponding to the target component in the dynamic image.
4. The monitoring method according to claim 3, characterized in that, Also includes: In response to the fault information indicating that the target component is in a fault state, the cause of the fault in the target component is determined based on the second operating status data; Determine the fault handling guidance information corresponding to the cause of the fault; In the dynamic image, the fault handling guidance information is displayed based on the position corresponding to the target component.
5. The monitoring method according to claim 1, characterized in that, Also includes: Obtain the production data of the physical production system within the target historical time period; Based on the production data, generate a production status corresponding to the target historical time period; In response to a selection instruction for the target historical time period, the production status is displayed in the dynamic image.
6. A monitoring device for a physical production system, characterized in that, include: An acquisition unit is used to acquire a three-dimensional digital model corresponding to the physical production system; as well as During the operation of the physical production system, the first operating status data of the physical production system is acquired in real time; wherein, the first operating status data includes the location information of the physical production system; The mapping unit is used to synchronously map the first operating status data to the three-dimensional digital model based on digital twin technology, so as to generate a dynamic image that is synchronized with the operation process of the physical production system in real time. The output unit is used to output the dynamic image for visual monitoring of the operation of the physical production system.
7. The monitoring system according to claim 6, characterized in that, The mapping unit is specifically used for: Based on the three-dimensional digital model, a static image corresponding to the physical production system is created; Based on digital twin technology, the location information is synchronously mapped to the virtual location information of the static image to generate a dynamic image that is synchronized in real time with the operation of the physical production system.
8. The monitoring system according to claim 6, characterized in that, The acquisition unit is also used for: Real-time acquisition of the second operating status data of the target component in the physical production system; The monitoring system further includes a determination unit, used to determine the fault information of the target component based on the second operating status data; The output unit is also configured to, in response to the fault information indicating that the target component is in a fault state, mark the position corresponding to the target component in the dynamic image as a fault state.
9. The monitoring system according to claim 8, characterized in that, The determining unit is further configured to: In response to the fault information indicating that the target component is in a fault state, the cause of the fault in the target component is determined based on the second operating status data; Determine the fault handling guidance information corresponding to the cause of the fault; The output unit is also used to display the fault handling guidance information in the dynamic image based on the position corresponding to the target component.
10. The monitoring system according to claim 8, characterized in that, The acquisition unit is also used for: Obtain the production data of the physical production system within the target historical time period; The determining unit is further configured to generate a production status corresponding to the target historical time period based on the production data; The output unit is also configured to display the production status in the dynamic image in response to a selection instruction for the target historical time period.