Digital Twin Field Simulation for Real-Scene Device Verification
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Solution Overview
Problem
The challenge of quickly and effectively testing new production devices in complex and dynamic field environments without disrupting other production units, and seamlessly integrating them into the field environment, is not adequately addressed by current virtual debugging and hardware in the loop (HIL) testing methods due to inconsistencies between virtual simulations and real-world environments.
Innovation Solution
A simulation system and method that generates a field environment model based on image information, synchronizes a simulation model with the real-time field environment, and presents it in a visual interface, utilizing environment sensing and process simulation capabilities to verify the device under test in a real scenario.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If virtual debugging and hardware in the loop (HIL) testing methods are used to accelerate device deployment, then testing speed is improved, but simulation accuracy deteriorates due to inconsistencies between virtual simulations and real-world environments
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the actual field environment that accurately replicates real-world conditions. This digital twin is built by capturing real environment data and generating corresponding 3D models, allowing the simulation to closely match the physical environment while maintaining accelerated testing speeds.
Solution Approach 2:
The system performs preliminary environment scanning and digital twin creation before the actual device deployment. By pre-building the virtual environment model with accurate geometric and physical properties, the simulation can proceed rapidly without sacrificing accuracy, as the environment data is already captured and processed in advance.
2Productivity
If traditional virtual simulation environments are used for device testing, then testing efficiency is improved, but adaptability to real field conditions deteriorates
Solution Approach 1:
The system dynamically adjusts simulation parameters by importing real field environment data including geometric structures, physical properties, and operational conditions. This allows the virtual environment to adapt to actual field conditions while maintaining efficient simulation processing through optimized parameter representation.
Solution Approach 2:
The field environment is divided into discrete scan stations and segmented into manageable 3D model components. Each segment can be independently processed and integrated into the overall digital twin, enabling efficient handling of large-scale environments while maintaining detailed adaptability to specific field conditions.
3Reliability
If comprehensive field environment testing is performed to ensure device compatibility, then reliability is improved, but time consumption increases
Solution Approach 1:
The patent replaces physical trial-and-error testing with virtual simulation-based verification. By substituting mechanical testing with computational simulation in the digital twin environment, the system achieves comprehensive device compatibility verification without the time consumption of physical prototyping and field testing iterations.
Solution Approach 2:
The digital twin platform serves multiple functions simultaneously: environment visualization, device simulation, collision detection, and operational validation. This multi-functionality allows comprehensive reliability testing to be performed in a single integrated virtual environment rather than requiring separate testing phases.
Data Source
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AI summary
Disclosed in the embodiments of the present invention are a simulation system and method for a device under test, and a field device, an electronic device and a medium. The system comprises a field device and a simulation device, wherein the field device is used for collecting image information of a field environment; the simulation device is used for generating a field environment model on the basis of the image information, arranging, in the field environment model, a simulation model of a device under test, and running the simulation model; and the field device is also used for presenting a real-time picture of the field environment in a visual interface, and presenting the simulation model in the real-time picture, the presented simulation model maintaining state synchronization with the simulation model, which is run in the simulation device. The state of a device under test is verified in a real scene environment in a simulation manner, thereby improving the simulation efficiency of the device under test.