Assembly Digital Twin Modeling With Surface Error Integration
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Solution Overview
Problem
Existing digital twin modeling methods fail to accurately account for geometric distribution errors of actual surfaces of parts, affecting the geometric and mechanical properties of assembled mechanical products.
Innovation Solution
A physical digital twin modeling method that generates a geometric distribution error surface, integrates it with an ideal model to form a geometric distribution error integrated model, and adds physical conditions to establish a physical digital twin model, accurately reflecting the geometric and physical properties of the actual assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ideal 3D CAD models are used for digital twin modeling, then the modeling process is simple, but the geometric distribution errors of actual surfaces are not accurately expressed
Solution Approach 1:
The patent measures and processes geometric distribution error data before assembly simulation to pre-establish accurate surface error models. By performing surface error measurement, data processing, and model construction in advance, the system integrates real geometric deviations into the digital twin model before the assembly simulation begins, thereby improving modeling accuracy without significantly complicating the overall process.
Solution Approach 2:
The patent creates a digital copy of the actual physical surface by measuring geometric distribution errors and constructing a surface error model that replicates real-world deviations. This digital surface error model accurately copies the physical imperfections of actual parts, allowing the virtual model to reflect true geometric variations while maintaining computational efficiency.
2Manufacturing precision
If actual surface geometric distribution errors are incorporated into the model, then the geometric and mechanical properties of the assembly are accurately predicted, but the modeling complexity increases
Solution Approach 1:
The patent divides the modeling process into distinct segments: surface error measurement, data processing, surface error model construction, and assembly simulation. By segmenting the complex task of incorporating geometric errors into manageable stages, the system maintains accuracy while organizing complexity into a structured workflow that can be systematically implemented and validated.
Solution Approach 2:
The patent introduces a surface error model as an intermediary between the ideal CAD model and the assembly simulation. This intermediate model serves as a bridge that translates measured geometric deviations into a format suitable for finite element analysis, thereby accurately capturing real-world geometric variations without directly complicating the assembly simulation process.
3Productivity
If finite element simulation is performed on ideal models, then the calculation process is straightforward, but the stress distribution differences due to actual surface variations are not captured
Solution Approach 1:
The patent prepares the surface error model in advance before conducting finite element simulation. By pre-processing geometric error data and integrating it into the model, the system ensures that actual surface variations are already incorporated into the mesh and boundary conditions, allowing straightforward simulation execution while capturing realistic stress distribution patterns.
Solution Approach 2:
The patent creates a digital replica of actual surface geometry by copying measured geometric distribution errors into the finite element model. This copied surface error information is then used to generate an accurate stress distribution pattern that reflects real-world contact conditions, thereby improving measurement precision without requiring complex simulation modifications.
Data Source
AI summary
The embodiments of the present disclosure provide a physical digital twin modeling method and apparatus for an assembly, an electronic device and a medium. The physical digital twin modeling method for the assembly includes: generating a geometric distribution error surface of an assembly surface of a part; establishing an ideal model of the part without the geometric distribution error surface; integrating the geometric distribution error surface with the ideal model to establish a geometric distribution error integrated model of the part; assembling the geometric distribution error integrated model on a computer to establish a geometric digital twin model; and adding physical conditions to the geometric digital twin model of the assembly to establish a physical digital twin model of the assembly.