Intelligent Workshop Parallel Control With Digital Twin Synchronization
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Solution Overview
Problem
Intelligent workshops face challenges in achieving flexibility and synchronous optimization due to high-frequency product changes, requiring real-time monitoring and control of production processes, which existing technologies fail to adequately address.
Innovation Solution
A parallel control method and system utilizing digital twin technology for an intelligent workshop, enabling real-time monitoring, prediction, and quick response to events through a three-dimensional visual platform, integrating soft and hard PLCs, MES modules, and SCADA systems for data synchronization and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If digital twin technology and parallel control simulation platform are implemented, then real-time monitoring and prediction capabilities are improved, but device complexity and system integration requirements worsen
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the physical workshop that mirrors the real system's structure, processes, and data flows. This virtual model enables real-time monitoring and prediction without adding physical complexity to the actual workshop equipment. The digital replica handles the computational burden while the physical system remains relatively simple.
Solution Approach 2:
The parallel control simulation platform acts as an intermediary layer between the physical workshop and the control system. It receives data from sensors and PLCs, processes it through the digital twin model, and generates control decisions. This intermediary absorbs the integration complexity, shielding the physical system from complex computational requirements.
2Reliability
If asynchronous periodicity synchronization mechanism is established between soft PLC and hard PLC, then communication reliability is improved, but control system complexity worsens
Solution Approach 1:
The system implements asynchronous periodic communication between soft PLC and hard PLC, where data exchange occurs at defined intervals rather than continuously. This periodic mechanism ensures reliable synchronization while reducing communication overhead and system complexity compared to continuous real-time synchronization.
Solution Approach 2:
The synchronization mechanism is designed to be dynamic and adaptive, adjusting communication frequencies and data exchange patterns based on actual system needs. This flexibility allows the system to maintain reliability during critical operations while reducing complexity during stable states.
3Loss of information
If three-dimensional visual parallel control platform is constructed, then real-time visualization and multi-view display capabilities are improved, but information processing requirements and system resource consumption worsen
Solution Approach 1:
The patent transitions from traditional two-dimensional monitoring interfaces to a three-dimensional visual platform that leverages the digital twin's spatial model. This dimensional enhancement provides comprehensive multi-view display capabilities, showing workshop operations from multiple perspectives simultaneously without requiring multiple separate systems.
Solution Approach 2:
The visual platform renders graphics and animations based on the existing digital twin model rather than creating separate visualization systems. This reuses the already-processed geometric and spatial data from the digital twin, reducing redundant computation and resource consumption while delivering enhanced visual information.
Data Source
AI summary
A parallel control method for an intelligent workshop is provided, comprising the following steps: step A: constructing a parallel control simulation platform; step B: establishing a parallel execution mechanism; and, step C: correcting and optimizing a parallel control system. A parallel control system for an intelligent workshop is provided, comprising: an MES module configured to issue production instructions to unit management modules; the unit management modules configured to convert the received production instructions into machine instructions and synchronously issue the machine instructions to underlying PLCs by a bus control network module, and drive the parallel control simulation platform and a field device to move by a soft PLC and a hard PLC; the bus control network module configured to establish a communication network among the MES module, an SCADA module, an industrial personal computer, physical devices and a whole-line simulation model; and, the SCADA module.