Construction of surface temperature monitoring system for laser machining parts based on digital twin

doi:10.3785/j.issn.1006-754X.2023.00.036

Chin J Eng Design

2023, Vol. 30

Issue (4): 409-418 DOI: 10.3785/j.issn.1006-754X.2023.00.036

【Subject Column】 Digital Twin·Intelligent Manufacturing

Construction of surface temperature monitoring system for laser machining parts based on digital twin

Zhangwei XIE^1,²(

),Xingbo ZHANG^1,²,Zhe XU^1,²,Yu ZHANG²,Fengyun ZHANG^1,²,Xi WANG^1,²,Pingping WANG²,Shufeng SUN^1,²(

),Haitao WANG¹,Jixin LIU³,Weili SUN³,Aixia CAO³

^1.School of Mechanical & Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
^2.Shandong Research Center of Laser Green and High Efficiency Intelligent Manufacturing Engineering Technology, Qingdao 266520, China
^3.School of Intelligent Manufacturing, Qingdao Huanghai University, Qingdao 266555, China

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Abstract

Digital twin is a concept that aims to establish a real-time mapping between physical space and virtual space. In order to expand the application of digital twin technology in laser machining, taking the processing of 7075 aluminum alloy by nanosecond laser marking machine as an example, the important role of finite element simulation in laser machining was expounded. However, due to the large computational amount of finite element simulation and the limited computing level of current computers, the simulation calculation time was long, which could not meet the real-time mapping required by digital twin technology. Therefore, a method of replacing finite element simulation with CGAN (conditional generative adversarial network) model was proposed. In this method, the CGAN model was trained by using the working condition images after image processing and the temperature cloud maps obtained by finite element simulation. Then, the trained CGAN model was packaged for building the surface temperature monitoring system for laser machining parts based on the digital twin. After completing the construction of the virtual end of the digital twin temperature monitoring system, the MQTT (message queuing telemetry transport) communication protocol was used to interact with the physical end to realize the remote monitoring and operation of the digital twin system. The surface temperature monitoring system for laser machining parts based on digital twin achieves the rapid simulation calculation of the surface temperature of parts, which solves the problems of long calculation time and inability to achieve real-time mapping by the finite element simulation. It can basically meet the monitoring and prediction of the surface temperature of laser machining parts, and has certain reference value in the field of laser machining temperature monitoring.

Key words： digital twin laser machining finite element simulation image processing conditional generative adversarial network (CGAN)

Received: 22 September 2022 Published: 04 September 2023

CLC:

TH 136

Corresponding Authors: Shufeng SUN E-mail: xiezw0331@163.com;sunshufeng@qut.edu.cn

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	Zhangwei XIE
	Xingbo ZHANG
	Zhe XU
	Yu ZHANG
	Fengyun ZHANG
	Xi WANG
	Pingping WANG
	Shufeng SUN
	Haitao WANG
	Jixin LIU
	Weili SUN
	Aixia CAO

Cite this article:

Zhangwei XIE,Xingbo ZHANG,Zhe XU,Yu ZHANG,Fengyun ZHANG,Xi WANG,Pingping WANG,Shufeng SUN,Haitao WANG,Jixin LIU,Weili SUN,Aixia CAO. Construction of surface temperature monitoring system for laser machining parts based on digital twin. Chin J Eng Design, 2023, 30(4): 409-418.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2023.00.036 OR https://www.zjujournals.com/gcsjxb/Y2023/V30/I4/409

基于数字孪生的激光加工零件表面温度监控系统的构建

数字孪生是一个旨在物理空间与虚拟空间之间建立实时映射的概念。为拓展数字孪生技术在激光加工领域的应用，以纳秒激光打标机加工7075铝合金为例，阐述了有限元仿真在激光加工领域的重要作用，但由于有限元仿真计算量较大且目前计算机的运算水平有限，存在仿真计算时间较长的问题，无法满足数字孪生技术所需的实时映射。为此，提出了利用CGAN（conditional generative adversarial network，条件生成对抗网络）模型代替有限元仿真的方法。该方法先利用图像化处理后的工况图像和由有限元仿真获得的温度云图对CGAN模型进行训练，随后将训练好的CGAN模型封装，用于构建基于数字孪生的激光加工零件表面温度监控系统。在完成数字孪生温度监控系统虚拟端的搭建后，使用MQTT（message queuing telemetry transport，消息队列遥测传输）通信协议与实体端进行数据交互，实现数字孪生系统的远程监控与操作。基于数字孪生的激光加工零件表面温度监控系统实现了零件表面温度的快速仿真计算，解决了有限元仿真计算时间长、无法实现实时映射的问题，基本能够满足激光加工零件表面温度的监控与预测，在激光加工温度监测领域具有一定的参考价值。

关键词： 数字孪生, 激光加工, 有限元仿真, 图像化处理, 条件生成对抗网络（CGAN）

Fig.1 Overall framework of surface temperature monitoring system for laser machining parts based on digital twin

Fig.2 Drawing, mapping and rendering of three-dimensional model of nanosecond laser marking machine

Fig.3 Training and use process of deep learning model

Fig.4 Image processing flow of laser machining condition data

Table 1 Comparison of the highest temperature on surface of laser machining parts under different working conditions

Fig.5 Image processing flow of transient thermodynamics finite element simulation result data

Fig.6 Dataset for CGAN model training

Fig.7 Quality changes in temperature cloud map generation during CGAN model training

Fig.8 Change curves of MSE and R² during CGAN model training

Fig.9 Comparison of partial temperature cloud maps generated by CGAN model with target temperature cloud maps

Table 2 Comparison of solution performance between finite element simulation and CGAN model

Fig.10 User interface of surface temperature monitoring system for laser machining parts

Fig.11 Nanosecond laser marking machine and real-time temperature monitoring system

Fig.12 Software performance test results of surface temperature monitoring system for laser machining parts

Fig.13 Frame rate test results of surface temperature monitoring system for laser machining parts


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