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浙江大学学报(工学版)
Journal of ZheJiang University (Engineering Science)  2022, Vol. 56 Issue (5): 843-855    DOI: 10.3785/j.issn.1008-973X.2022.05.001
    
Digital twin mapping modeling and method of monitoring and simulation for reconfigurable manufacturing system
Bo-han LENG1,2(),Tang-bin XIA1,2,*(),He SUN1,2,Hao WANG1,2,Li-feng XI1,2
1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2. Fraunhofer Project Center for Smart Manufacturing at Shanghai Jiao Tong University, Shanghai 201306, China
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Abstract  

Digital twin and manufacturing simulation integrated platform (DTMSIP) architecture for reconfigurable manufacturing system (RMS) was proposed, aiming at the application problem of digital twin on RMS. DTMSIP was highly adapted to RMS’s dynamic reconfiguration and can be used for simulation analysis in RMS configuration design. Digital twin mapping for RMS was modeled. By defining twinning entity (TE), heterogeneous multi-source data integration in RMS shop-floor was realized and digital twin mapping for machine tools and configuration was established. The application procedure of digital twin-based RMS reconfiguration was proposed. DTMSIP served the purpose of assisting RMS reconfiguration through iteration of cyber physical fusion and iteration of configuration simulation. In order to validate the proposed method, Unreal Engine 4 (UE4) was adopted to implement DTMSIP software for a modular RMS. Current configuration and four planned configurations were input to DTMSIP software for simulation. Quantitative and comprehensive analysis was performed on the configurations taking into consideration cost of reconfiguration, cycle time and line balance, contributing to accelerate RMS reconfiguration design processes.

Key words： digital twin      reconfigurable manufacturing system      mapping modeling      real-time simulation      system reconfiguration     
Received: 20 October 2021      Published: 31 May 2022
CLC:  TH 181  
Fund:  国家自然科学基金资助项目(51875359)；上海市“科技创新行动计划”自然科学基金资助项目(20ZR1428600)；上海商用飞机系统工程科创中心联合研究基金资助项目(FASE-2021-M7)；教育部-中国移动联合基金建设项目(MCM20180703)；上海交通大学深蓝计划基金资助项目(SL2021MS008)；中船-交大海洋装备前瞻创新基金(22B010432)
Corresponding Authors: Tang-bin XIA     E-mail: lamberhand@gmail.com;xtbxtb@sjtu.edu.cn
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Bo-han LENG
Tang-bin XIA
He SUN
Hao WANG
Li-feng XI
Cite this article:

Bo-han LENG,Tang-bin XIA,He SUN,Hao WANG,Li-feng XI. Digital twin mapping modeling and method of monitoring and simulation for reconfigurable manufacturing system. Journal of ZheJiang University (Engineering Science), 2022, 56(5): 843-855.

URL:

https://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2022.05.001     OR     https://www.zjujournals.com/eng/Y2022/V56/I5/843


面向可重构制造的数字孪生映射建模与监控仿真

针对数字孪生在可重构制造系统（RMS）的应用问题，提出面向RMS的数字孪生与制造仿真一体化平台（DTMSIP）架构. DTMSIP架构充分适配RMS动态重构特性，可以在RMS构型设计中实现仿真分析. 对面向RMS的数字孪生映射进行建模，通过引入孪生实体（TE），实现RMS车间的多源异构数据集成，并分别建立机床与构型的数字孪生映射. 建立数字孪生方法在RMS重构中的应用流程，通过信息物理融合迭代与构型仿真优化迭代，DTMSIP可以服务于RMS的系统重构. 为了验证所提出方法的可行性，使用虚幻引擎四（UE4）为一套实际的模块化RMS构建数字孪生平台，并将当前构型以及4种规划构型作为仿真输入. 通过分析重构成本、生产周期与系统平衡率3项指标，实现对构型的量化综合分析，实现了重构设计流程加速.


关键词： 数字孪生,  可重构制造系统,  映射建模,  实时仿真,  系统重构 
Fig.1 Architecture of digital twin and manufacturing simulation integrated platform for reconfigurable manufacturing system
孪生实体类型 工况表征值 孪生数据源 数据传输方法 数字孪生表现方法
布尔状态孪生实体 {True, False} RFID、I/O寄存器、PLC Modbus、RTDE、TCP/IP、CPS API 运动、碰撞体阻挡或放行
枚举状态孪生实体 SetTE PLC、上位机软件状态判定 Modbus、RTDE、TCP/IP、CPS API 运动、UI图标
数值变量孪生实体 ValTE 机器人控制、PLC Modbus、RTDE、TCP/IP、CPS API 运动、数据看板
Tab.1 Method of behaviour mapping for machine tools based on TE
Fig.2 Procedure of DTMSIP-based RMS reconfiguration
Fig.3 T-shaped RMS modular machine tool base
Fig.4 RMS configuration resolving
Fig.5 Current RMS configuration and four planned configurations to be previewed through simulation
Fig.6 Gantt chart for actual production and simulation of current RMS configuration
仿真构型 $ C_{{\text{Rec}}}^\prime $构成 $ C_{{\text{Rec}}}^\prime $/CNY ${T_{{\text{Bat}}}}$/s ${\text{Bal}}$/%
当前构型 ? ? 518.1 51.3
规划构型① ${\text{PI} }({M^{\rm{F}}}) + P({\text{Base} })$ 280 000 476.4 63.0
规划构型② ${\text{PI} }({M^{\rm{F}}}) + {\text{PI} }({M^{{\rm{A}}/{\rm{G}}} }) + 2P({\text{Base} })$ 420 000 449.9 63.0
规划构型③ ${\text{PI} }({M^{\rm{F}}}) + {\text{PI} }({M^{{\rm{A}}/{\rm{G}}} }) + 2P({\text{Base} })$ 420 000 451.6 63.0
规划构型④ ${\text{PI} }({M^{\rm{F}}}) + {\text{PI} }({M^{\rm{E}}}) + {\text{PI} }({M^{{\rm{A}}/{\rm{G}}} }) + 3P({\text{Base} })$ 820 000 419.9 77.4
Tab.2 Simulation result of four planned configurations
Fig.7 Gantt chart for simulation and actual production of accepted configuration
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