Digital Twin Production Line Debugging for Parallel Integration
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Solution Overview
Problem
Current automatic production line development methods lead to system-level problems and increased costs due to serial debugging processes, where issues are exposed only during integration, causing delays and inefficiencies in debugging and verification.
Innovation Solution
An approximate physical simulation integrated debugging method based on digital twinning, which involves building simulation models, generating twins, performing off-line debugging, and using hardware-in-the-loop and device-in-the-loop debugging to optimize control programs and reduce errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If serial debugging mode is used from mechanical design to software verification, then design problems are exposed gradually during integration and debugging, but system-level problems cause functional integrity and control logic accuracy to fail, reducing production line system performance
Solution Approach 1:
The patent applies preliminary action by performing offline simulation debugging of the digital twin model before actual production deployment. The control logic and system integration are verified in the virtual environment first, allowing problems to be detected and resolved before affecting real production operations. This ensures functional integrity and control logic accuracy are established beforehand, preventing system-level failures in the actual production line.
2Productivity
If the whole system is put into production after simulation debugging, then entity device production can begin, but problems after replacement require re-debugging and iteration, prolonging development period and increasing cost
Solution Approach 1:
The patent uses copying by creating a digital twin model that replicates the physical production line's structure, behavior, and control logic. This virtual copy allows complete debugging and verification offline before deployment. When the digital twin is successfully debugged, it can be replaced with the actual entity device without requiring re-debugging, as all issues have already been resolved in the virtual model. This eliminates iterative re-debugging cycles and significantly reduces development time.
3Manufacturing precision
If offline simulation debugging is performed on local production line twin, then local component twins can be optimized and replaced with entity components, but communication and synchronization between virtual and real systems must be established
Solution Approach 1:
The patent applies segmentation by dividing the production line into multiple local components, each with its own digital twin model. Offline simulation debugging is performed on individual local component twins independently, allowing precise optimization of each component's control logic and behavior. Once a local component twin is successfully debugged, it can be replaced with the corresponding entity component. This segmented approach enables high debugging precision while managing system integration complexity through modular, independent verification of each component.
Data Source
AI summary
Disclosed is an approximate physical simulation integrated debugging method based on digital twinning, which includes the following steps of: a production line simulation model building step, a twinning step, a system debugging step, a hardware-in-the-loop debugging step, and a device-in-the-loop debugging step. The approximate physical simulation integrated debugging system based on digital twinning includes a production line simulation model building module, a twinning module, a system debugging module, a hardware-in-the-loop debugging module, and a device-in-the-loop debugging module. According to the approximate physical simulation integrated debugging method and system based on digital twinning, since a local component twin after being successfully debugged is replaced with an entity component, when a problem occurs after replacement, only the local component twin needs to be debugged and optimized again, thus saving time and reducing cost.