3D Digital Twin Process Diagnosis for Remote Machining Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current remote expert assistance for processing devices is limited by the inability to observe the current state or perform real-time simulation and analysis, leading to delayed and inconvenient troubleshooting.
Innovation Solution
A process diagnosis system incorporating a digital twin calculation unit that obtains and simulates vibration and cutting-related parameters, generating a three-dimensional calculation result, which is then displayed and analyzed by a process diagnosis calculation unit and remote calculation analysis unit respectively, enabling intuitive and collaborative remote diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If remote expert only observes information on device dashboard through frame, then device complexity is reduced, but measurement precision and diagnosis accuracy deteriorate
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the processing device that replicates its operational state, vibration characteristics, and processing parameters. This virtual model allows remote experts to observe and analyze device behavior with high precision without adding physical complexity to the actual device. The digital twin serves as an accurate replica that can be remotely accessed and analyzed.
Solution Approach 2:
The system introduces a simulation server as an intermediary between the processing device and remote expert. This intermediary performs real-time simulation calculations based on device data and presents the results to remote experts in an intuitive format, bridging the gap between raw device data and actionable diagnostic insights without requiring direct complex interaction with the device itself.
2Device complexity
If remote expert cannot perform real-time simulation and analysis, then device complexity is reduced, but loss of time in troubleshooting increases
Solution Approach 1:
The system pre-establishes a digital twin model and simulation environment before actual troubleshooting occurs. When abnormalities are detected, the remote expert can immediately perform simulations and analyses on the pre-configured digital twin without waiting for device setup or data collection, enabling rapid diagnosis and reducing troubleshooting time.
Solution Approach 2:
The patent replaces physical presence and manual inspection with virtual simulation and digital analysis. Remote experts use computational models and simulation software to analyze device behavior, substituting the need for physical device interaction and manual troubleshooting procedures with automated simulation-based diagnostics that provide faster results.
3Ease of operation
If remote expert cannot observe current state of processing device, then ease of operation is maintained, but reliability of remote assistance deteriorates
Solution Approach 1:
The digital twin creates a faithful virtual replica of the processing device's current state, including operational parameters, vibration patterns, and processing conditions. This copy allows remote experts to observe and analyze device behavior with the same accuracy as if they were physically present, maintaining diagnostic reliability while preserving the ease of remote access.
Solution Approach 2:
The system continuously updates the digital twin with real-time data from the processing device, creating a feedback loop that ensures the virtual model accurately reflects the current device state. This continuous synchronization allows remote experts to receive up-to-date information about device conditions, maintaining high diagnostic reliability without requiring physical presence.
Data Source
AI summary
A process diagnosis system includes a digital twin calculation unit, a process diagnosis calculation unit, and a remote calculation analysis unit. The digital twin calculation unit obtains a vibration-related parameter and a cutting-related parameter of a processing device, and performs a simulation calculation for the vibration-related parameter, the cutting-related parameter and a three-dimensional model corresponding to the processing device to generate a three-dimensional calculation result. The process diagnosis calculation unit receives a three-dimensional calculation result and displays the three-dimensional calculation result. The remote calculation analysis unit receives the three-dimensional calculation result, and performs a simulation analysis for the three-dimensional calculation result to generate an analysis result.