Digital Twin Simulation for Production Line Alignment Variability
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Solution Overview
Problem
Current digital twin systems in automobile assembly and production lines face challenges with small positional discrepancies between virtual models and real equipment, reducing simulation accuracy and requiring additional man-hours for transition to actual construction.
Innovation Solution
A simulation device and method that generates random numbers based on different probability distribution functions for physical parameters, repeatedly simulating a digital twin-based virtual environment to derive result values by statistical probability, using techniques like auto-scaling and auto-snapping to adjust object sizes and connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-precision measurement tools and advanced techniques are used during installation to improve alignment between virtual models and real equipment, then manufacturing precision is improved, but device complexity and loss of time increase
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the production facility that replicates the physical environment. By generating random numbers based on probability distribution functions representing actual environmental variations, the virtual model accurately mirrors real-world conditions without requiring complex measurement tools during installation, thus reducing device complexity while maintaining alignment precision
Solution Approach 2:
The patent transforms fixed parameter values into probabilistic parameters by generating random numbers according to probability distribution functions. This allows the virtual environment to dynamically represent environmental variations (temperature, humidity, vibrations) that affect positional accuracy, improving manufacturing precision through parameter variability rather than through complex measurement systems
2Manufacturing precision
If high-precision measurement tools and advanced techniques are used during installation to improve alignment between virtual models and real equipment, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary actions by pre-generating random numbers based on probability distribution functions that represent environmental variations. This allows the virtual environment to be pre-configured with realistic parameters before actual simulation, eliminating the need for time-consuming measurements and adjustments during installation while maintaining high alignment precision
Solution Approach 2:
By creating a digital twin that copies the physical facility's environmental characteristics through probabilistic modeling, the system achieves accurate alignment without requiring extensive measurement and adjustment time. The virtual model is configured once with probability distributions that automatically represent real-world variations, significantly reducing installation time while maintaining precision
3Measurement precision
If random numbers are generated based on probability distribution functions and simulations are repeatedly executed, then simulation accuracy is improved, but productivity decreases
Solution Approach 1:
The patent employs periodic action by generating random numbers a predetermined number of times according to probability distribution functions and repeatedly executing simulations with these generated values. This structured repetition allows statistical analysis of simulation results, improving measurement precision through multiple samples while maintaining productivity through automated, systematic execution rather than ad-hoc testing
4Reliability
If the virtual environment is fixed based on generated random numbers and simulations are repeatedly executed, then reliability is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary action by generating random numbers and fixing the virtual environment configuration before conducting repeated simulations. This pre-establishment of the virtual environment based on probabilistic models ensures reliability through consistent, reproducible conditions while reducing total time by avoiding reconfiguration during each simulation run
Data Source
AI summary
A simulation device for a digital twin-based virtual environment includes an input unit for inputting information required for constructing and simulating a virtual environment for a production facility, a memory including an object library for each of a plurality of objects to be disposed in a digital twin (DT)-based virtual space, a DT control unit performing DT simulation on the DT-based virtual environment constructed based on the object library, and an output unit outputting a simulation execution result. The DT control unit includes a DT virtual environment construction unit constructing the DT-based virtual environment, a DT simulation setup unit setting DT simulation setup information on the virtual environment, and a DT simulation execution unit executing a simulation on a target object in the virtual environment, based on a random number generated according to a number of predefined simulation settings and probability, based on the simulation setup information.