Intelligent manufacturing application experiment table based on digital twinning technology

Abstract

The utility model discloses an intelligent manufacturing application experiment table based on digital twinborn technology belongs to teaching equipment technical field. To solve the problem of the fragmentation of the function of the existing experiment table, the missing factory level whole process closed loop, the experiment table includes: material temporary storage platform, parallel robot, transport mechanism, series mechanical hand, analog processing unit, visual detection device, AGV dolly and stereoscopic warehousing unit are connected in turn, communication component and digital twinborn display terminal. Through the construction "processing-detection-warehousing" whole process material closed loop, eliminate the disjointedness of teaching scene and actual production, adopt intelligent gateway to realize the data synchronization of PLC and twinborn terminal in 200ms, support virtual instruction reverse control physical actuating mechanism, modular design is compatible with multi -brand robot and protocol extension. Through dynamic 3D model perspective equipment operation mechanism, the teaching cognitive efficiency is improved obviously.

Description

Technical Field

[0001] This application belongs to the field of teaching equipment technology, and in particular relates to an intelligent manufacturing application experimental platform based on digital twin technology. Background Technology

[0002] With the development of automation technology, intelligent manufacturing teaching and experimental equipment is playing an increasingly important role in the training of engineering and technical personnel. However, existing intelligent manufacturing experimental platforms mainly suffer from the following shortcomings:

[0003] Functional fragmentation problem

[0004] Traditional experimental benches often employ single-function modular designs (such as independent PLC control consoles, robotic arm training units, etc.), lacking end-to-end material handling capabilities. For example:

[0005] A collaborative robot teaching platform based on digital twins disclosed in Chinese patent CN216623588U only includes a six-axis robot and a simple conveyor belt, which cannot simulate the entire process of processing-inspection-warehousing.

[0006] The training equipment often lacks core components of modern factories such as automated warehousing and AGV transportation, resulting in a disconnect between the teaching scenario and actual production.

[0007] Existing digital twin teaching equipment has limitations in one-way monitoring: it only supports 3D model visualization and cannot control physical devices through virtual operation; the data synchronization delay between digital models and physical devices often exceeds 500ms (such as browser rendering schemes based on WebGL), making it difficult to achieve accurate virtual-physical linkage. Utility Model Content

[0008] The technical problem to be solved by this utility model is to provide an intelligent manufacturing application experimental platform based on digital twin technology to overcome the shortcomings of the existing technology, and aims to solve at least one of the above-mentioned technical problems.

[0009] The technical solution adopted by this utility model to solve its technical problem is:

[0010] 1. An intelligent manufacturing application experimental platform based on digital twin technology, including:

[0011] The physical actuator consists of a material storage platform, a parallel robot, a material transport mechanism, a serial handling manipulator, a simulated processing unit, a vision inspection device, a track-type mobile transport trolley, and a material storage unit connected in sequence.

[0012] Communication components: including a smart gateway, equipped with an industrial Ethernet interface, a WIFI module and a 4G communication module;

[0013] The PLC controller is connected to each unit of the physical actuator via a data cable;

[0014] The digital twin display terminal connects to the smart gateway and PLC controller via a network port to display a 3D model that is identical to the physical actuator.

[0015] The smart gateway connects to the PLC controller via an RS485 interface using the Modbus RTU protocol; the digital twin display terminal establishes bidirectional communication links with both the smart gateway and the PLC controller via an industrial Ethernet switch.

[0016] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the material transport mechanism includes:

[0017] The conveyor belt device has material positioning sensors installed on its surface;

[0018] The variable speed motor is mechanically connected to the conveyor belt device via a coupling.

[0019] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the visual inspection device includes:

[0020] Industrial camera, mounted on an adjustable bracket;

[0021] A ring light source is positioned around the industrial camera.

[0022] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the simulated processing unit includes:

[0023] The pneumatic exchange worktable is equipped with a dual-station fixture;

[0024] The simulated spindle head is positioned above the pneumatic exchange table and is driven to rotate by a servo motor.

[0025] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the automatic stacker includes:

[0026] The planar module is vertically installed on the side of the automated shelving unit and includes a lifting module and a horizontal module.

[0027] The telescopic forks, including a telescopic cylinder and a pneumatic gripper, are connected to the motion output end of the planar module.

[0028] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the material storage unit includes a three-dimensional shelf and an automatic stacker, wherein the three-dimensional shelf has a 4-layer, 3-column structure.

[0029] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the digital twin display terminal is a liquid crystal display screen, and the back is provided with an RJ45 network port and an HDMI interface.

[0030] Preferably, in the intelligent manufacturing application experimental platform based on digital twin technology of this utility model, the PLC controller is integrated in the electrical control cabinet, and the surface of the cabinet is equipped with an HMI touch screen.

[0031] Preferably, the intelligent manufacturing application experimental platform based on digital twin technology of this utility model is characterized in that: the intelligent gateway has a built-in STM32F407 main control chip, and its RS485 interface is directly connected to the communication port of the PLC controller; the RJ45 network port of the digital twin display terminal is connected to an industrial Ethernet switch through a CAT6 network cable, and the network ports of the PLC controller and the intelligent gateway are both connected to the same switch.

[0032] The beneficial effects of this utility model are:

[0033] (1) This experimental platform adopts the full-process automated material handling capability (solving the problem of functional fragmentation). It forms a physical cascade through material storage platform → parallel robot → transportation mechanism → serial manipulator → processing / inspection unit → AGV → three-dimensional shelf, realizing a factory-level material flow closed loop.

[0034] (2) Adopting a two-way communication hardware architecture: The smart gateway supports Modbus / OPC UA / MQTT protocol conversion to achieve data synchronization between PLC and digital twin terminal within 200ms;

[0035] Virtual operation commands are directly connected to the PLC's DI module via a hardware gateway to drive physical actuators (such as the movement of a robotic arm and the start and stop of an AGV).

[0036] (3) Modular and scalable structure (eliminating system closure)

[0037] Mechanically compatible design: The actuator adopts a standard flange interface (ISO 9409-1), which allows for quick replacement of robots from different brands;

[0038] The electrical control cabinet has a 20% I / O margin (≥3 slots for Siemens S7-1200 expansion modules).

[0039] Protocol extension capability: The smart gateway supports custom protocol plugins (with a reserved TF card slot for loading configuration firmware).

[0040] (4) Visualized cognitive enhancement (improving teaching efficiency)

[0041] Transparent hardware design: The electrical control cabinet uses an acrylic transparent door panel to intuitively display the PLC wiring logic;

[0042] An observation window is provided on the side panel of the stacker crane to reveal the lead screw-stepper motor transmission structure.

[0043] Dynamic twin terminal: A 21.5-inch display screen with a pneumatic lifting bracket (tilt angle adjustable from 0-30°) presents the equipment's operating status from multiple perspectives;

[0044] 3D model cutaway view of key components (e.g. showing the air path of the vacuum suction cup). Attached Figure Description

[0045] The technical solution of this application will be further described below with reference to the accompanying drawings and embodiments.

[0046] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application;

[0047] Figure 2 This is a schematic diagram of the connection relationship of the communication components in an embodiment of this application;

[0048] The attached figures are labeled as follows:

[0049] Parallel robot 1, material storage platform 2, material transport mechanism 3, serial handling robot 4, simulated processing unit 5, vision inspection device 6, track-type mobile transmission trolley 7, material storage unit 8. Detailed Implementation

[0050] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0051] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this application. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0052] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0053] The technical solution of this application will now be described in detail with reference to the accompanying drawings and embodiments.

[0054] Example: This specific implementation provides an intelligent manufacturing application experimental platform based on digital twin technology. The overall structure of the experimental platform refers to... Figure 1 The intelligent manufacturing experimental platform includes physical actuators, communication components, and a digital twin display terminal. Each unit is fixed to an aluminum profile experimental platform frame with bolts, and the bottom of the frame is equipped with casters and leveling feet.

[0055] Specifically, the physical actuators include the following:

[0056] (1) Material storage platform 2: Multiple evenly distributed material positioning slots of 50mm×50mm×10mm are opened on the platform to facilitate the installation and debugging of the actuator position.

[0057] Bottom sensor: An Omron E3Z-D61 photoelectric sensor is embedded in the bottom of the slot and connected to the PLC controller DI module via wires.

[0058] (2) Parallel Robot 1: The base is fixed to the table via a flange, and the arm span radius is 500mm using a Delta structure;

[0059] End effector: pneumatic two-finger gripper SMCMHZ2-10D, with the air hose connected to the pneumatic valve island via a cable chain.

[0060] (3) Material transport mechanism 3: including a conveyor belt device, wherein the distance between the active roller and the driven roller is 800mm and the belt width is 100mm; speed regulating motor: the speed reducer motor has a power of 60W and a speed ratio of 1:10, and is directly connected to the active roller through a coupling.

[0061] Positioning sensor: Keyence FS-N11N through-beam fiber optic sensor is mounted on the brackets on both sides of the belt.

[0062] (4) Serial handling robot 4, four-axis SCARA structure Yamaha YK400XG, fixed with base bolts;

[0063] End tool: Vacuum suction cup assembly SMCZPT06BG, connected to the vacuum generator via PU tubing.

[0064] (5) Simulation processing unit 5: Pneumatic exchange worktable: Dual-station rotary platform with a diameter of 200mm, driven by cylinder SMCCDQ2B20-30D to switch 180°;

[0065] Simulated spindle head: The simulated drill bit has a diameter of 10mm and a maximum speed of 3000rpm, driven by a Panasonic MINASA6 servo motor.

[0066] (6) Visual inspection device 6: including an industrial camera, using a 5-megapixel CMOS camera mounted on an adjustable bracket with a travel of ±15°;

[0067] Ring light source: An 80mm diameter white LED light source that surrounds the camera lens via a clamp.

[0068] (7) Track-type mobile transmission trolley: Body: 2mm thick aluminum alloy sheet metal bending and forming size 300mm×200mm×150mm;

[0069] Control panel: Surface-mounted emergency stop button (Schneider XB2-BS542C) and green start button;

[0070] Walking mechanism: A 24V / 50W DC motor drives rubber wheels to run along a preset U-shaped track with a width of 30mm.

[0071] (8) Material storage unit 8: including three-dimensional rack: 4 layers and 3 columns of square tube welded frame, with a layer height of 150mm and a column width of 200mm;

[0072] Automated stacker crane:

[0073] Lifting guide rail: HIWIN HGH15CA linear slide rail, vertically mounted;

[0074] Telescopic forks: Double fork structure with a stroke of 200mm, driven by a 57HS09 stepper motor via a lead screw with a lead of 5mm.

[0075] It also includes communication components, see reference Figure 2 ,include:

[0076] Smart gateway: The front panel features an RJ45 network port, SIM card slot, and WIFI antenna; the internal circuit board integrates an STM32F407 main control chip, supporting Modbus RTU protocol and RS485 interface connection to PLC.

[0077] PLC controller:

[0078] The Siemens S7-1200 CPU1214C is installed in the electrical control cabinet, which has an IP54 protection rating.

[0079] Wiring relationships: DI module: connects to material storage platform sensor and conveyor belt sensor; DO module: drives pneumatic valve island and servo motor enable signal; Ethernet port: connects to the smart gateway via CAT6 network cable.

[0080] The digital twin display terminal includes a 21.5-inch LCD screen with a resolution of 1920×1080. Rear interfaces include: an HDMI interface for connecting to an industrial PC with an Intel i5-8500 graphics card output; an RJ45 network port for connecting to a PLC and smart gateway via a switch; and a screen bracket with a pneumatic lifting rod with a stroke of 300mm, supporting tilt angle adjustment.

[0081] The operation process of this experimental platform is as follows:

[0082] Step 1: Material receiving process begins

[0083] 1. The operator places the material into the positioning slot of material storage table 2;

[0084] 2. The bottom photoelectric sensor detects the position signal and transmits it to the 11DI module of the PLC controller via a wire.

[0085] In the 3D model of the digital twin terminal, the corresponding slot of the material storage platform is highlighted with a red indicator, and the status bar displays "Material in place".

[0086] Step 2: Parallel robot grasping and transferring

[0087] 3. The PLC controls the pneumatic valve island to start, driving the pneumatic gripper at the end of the parallel robot 1 to grab the material;

[0088] 4. The robot arm extends and moves to place the material onto the conveyor belt of the material transport mechanism 3.

[0089] The Unity3D engine renders the robot's motion trajectory in real time, and the interface synchronously displays joint angles such as θ1 = 30°, θ2 = 45°.

[0090] Step 3: Conveyor Belt Positioning and Visual Inspection

[0091] 5. The conveyor belt speed-regulating motor starts at 60W and transports materials to the inspection station;

[0092] 6. When the Keyence FS-N11N fiber optic sensor is triggered to the position signal, the PLC pauses the conveyor belt.

[0093] 7. The industrial camera of the vision inspection device 6 acquires material images under a ring light source.

[0094] The 3D model of the conveyor belt lights up with its running indicator light, and the twin terminal displays a real-time camera view and marks the detection area.

[0095] Step 4: Processing by serial robotic arms

[0096] 8. The PLC starts the 4-vacuum suction cups of the series handling robot via the DO module to pick up materials;

[0097] 9. The robotic arm moves the material to the simulated processing unit 5;

[0098] 10. Pneumatic exchange worktable switching position, servo motor driven simulated action (such as drill bit executing drilling speed of 3000rpm, Z-axis travel of 50mm).

[0099] A 3D model provides a cross-sectional view of the spindle's internal structure and dynamically displays real-time data on the drill bit's depth of penetration.

[0100] Step 5: AGV Transfer and Automated Warehousing

[0101] 11. The processed materials are placed by a series of robotic arms onto a track-type mobile transfer trolley 7;

[0102] 12. The AGV DC motor starts and runs along the U-shaped track to the material storage unit 8;

[0103] 13. The automatic stacker crane receives instructions:

[0104] The planar module moves vertically to the target layer, such as layer 3.

[0105] The telescopic forks are driven by a stepper motor, with a stroke of 200mm when extended, and the pneumatic grippers grab materials and store them in the 4-layer, 3-column rack.

[0106] The AGV's movement path is drawn in real time on the digital twin map, with coordinate updates at a frequency of 10Hz;

[0107] The stacker crane 3D model highlights the current operating location, such as "3-2".

[0108] Step 6: Extended Functionality of Digital Twin Reverse Control

[0109] 14. The user clicks "Retrieve Material" on the twin terminal and sends the command to the smart gateway 12;

[0110] 15. The gateway forwards instructions to the PLC's DI module via the Modbus RTU protocol;

[0111] 16. The PLC controls the stacker crane to retrieve materials from the designated location, which are then transported back to the temporary storage platform via AGV, completing the closed loop.

[0112] Digital twin data flow: The intelligent gateway collects the PLC's IO status data → encapsulates it via the Modbus protocol → transmits it to the industrial control computer via network cable → the Unity3D engine parses the data to drive the 3D model → the LCD screen displays the robot's movement trajectory in real time.

[0113] Based on the above-described preferred embodiments according to this application, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this application. The technical scope of this application is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. An intelligent manufacturing application experimental platform based on digital twin technology, characterized in that, include: The physical execution mechanism is composed of a material storage platform (2), a parallel robot (1), a material transport mechanism (3), a serial handling robot (4), a simulated processing unit (5), a vision inspection device (6), a track-type mobile transmission trolley (7), and a material storage unit (8) connected in sequence. Communication components: including a smart gateway, equipped with an industrial Ethernet interface, a WIFI module and a 4G communication module; The PLC controller is connected to each unit of the physical actuator via a data cable; The digital twin display terminal connects to the smart gateway and PLC controller via a network port to display a 3D model that is consistent with the physical actuator; The smart gateway connects to the PLC controller via an RS485 interface using the Modbus RTU protocol; the digital twin display terminal establishes bidirectional communication links with both the smart gateway and the PLC controller via an industrial Ethernet switch.

2. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 1, characterized in that, The material transport mechanism (3) includes: The conveyor belt device has material positioning sensors installed on its surface; The variable speed motor is mechanically connected to the conveyor belt device via a coupling.

3. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 2, characterized in that, The visual inspection device (6) includes: Industrial camera, mounted on an adjustable bracket; A ring light source is positioned around the industrial camera.

4. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 3, characterized in that, The simulated processing unit (5) includes: The pneumatic exchange worktable is equipped with a dual-station fixture; The simulated spindle head is positioned above the pneumatic exchange table and is driven to rotate by a servo motor.

5. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 4, characterized in that, The material storage unit (8) includes an automated stacker crane, which comprises: The planar module is vertically installed on the side of the automated shelving unit and includes a lifting module and a horizontal module. The telescopic forks, including a telescopic cylinder and a pneumatic gripper, are connected to the motion output end of the planar module.

6. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 5, characterized in that, The material storage unit (8) also includes a three-dimensional shelf, which has a 4-layer, 3-column structure.

7. The intelligent manufacturing application experimental platform based on digital twin technology according to any one of claims 1-6, characterized in that, The digital twin display terminal is an LCD screen with an RJ45 network port and an HDMI interface on the back.

8. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 7, characterized in that, The PLC controller is integrated into the electrical control cabinet, and the surface of the cabinet is equipped with an HMI touch screen (10).

9. The intelligent manufacturing application experimental platform based on digital twin technology according to claim 8, characterized in that: The intelligent gateway (12) has a built-in STM32F407 main control chip, and its RS485 interface is directly connected to the communication port of the PLC controller (11); the RJ45 network port of the digital twin display terminal is connected to the industrial Ethernet switch through a CAT6 network cable, and the network ports of the PLC controller (11) and the intelligent gateway (12) are both connected to the same switch.

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