Please wait a minute...
工程设计学报
Chinese Journal of Engineering Design  2024, Vol. 31 Issue (4): 538-546    DOI: 10.3785/j.issn.1006-754X.2024.03.186
Whole Machine and System Design     
Research on automatic winding system of thermal battery insulation cotton based on digital twin
Baoyin SUN1,2(),Yongping HAO1,2(),Yuhan ZHANG1,2,Ziyang LI1
1.School of Mechanical Engineering, Shenyang Ligong University, Shenyang 110159, China
2.Liaoning Province Key Laboratory of Advanced Manufacturing Technology and Equipment, Shenyang 110159, China
Download: HTML     PDF(5589KB)
Export: BibTeX | EndNote (RIS)      

Abstract  

In order to improve the efficiency and quality of thermal battery insulation cotton winding process, an automatic insulation cotton winding system based on digital twin technology was developed. Firstly, the digital twin mapping structure model of the automatic winding device of insulation cotton was created by NX MCD software, and the information interaction and state detection between the model and the actual physical device and control device were realized through TIA Portal software, so as to reflect the winding action and state more accurately. Then, the mechanical model of automatic winding process of insulation cotton was established to analyze the winding mechanism. Nextly, the influence of winding tension and stack rotation speed on the winding effect of insulation cotton was studied by finite element dynamics simulation, and the simulation results were imported into the digital twin system to optimize the digital twin structure layer and control layer program. Finally, the automatic winding of insulation cotton was realized successfully through joint debugging and the thermal battery stack with good coating effect was produced. The research method can effectively improve the research efficiency, accelerate the design process and reduce the trial-and-error cost, which can provide a reference for the research of automatic assembly of winding packaging.

Key words： automatic winding system      winding mechanism      digital twin      finite element dynamics simulation     
Received: 03 July 2023      Published: 26 August 2024
CLC:  TH 122  
Corresponding Authors: Yongping HAO     E-mail: 664495954@qq.com;yphsit@126.com
Service
E-mail this article
Add to my bookshelf
Add to citation manager
E-mail Alert
RSS
Articles by authors
Baoyin SUN
Yongping HAO
Yuhan ZHANG
Ziyang LI
Cite this article:

Baoyin SUN,Yongping HAO,Yuhan ZHANG,Ziyang LI. Research on automatic winding system of thermal battery insulation cotton based on digital twin. Chinese Journal of Engineering Design, 2024, 31(4): 538-546.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2024.03.186     OR     https://www.zjujournals.com/gcsjxb/Y2024/V31/I4/538


基于数字孪生的热电池保温棉自动缠绕系统研究

为提高热电池保温棉缠绕工艺的效率与质量，基于数字孪生技术开发了一种保温棉自动缠绕系统。首先，利用NX MCD软件创建保温棉自动缠绕装置的数字孪生映射结构模型，并通过TIA Portal软件实现了模型与实际物理装置以及控制设备之间的信息交互和状态检测，以更准确地反映缠绕动作及状态。然后，建立保温棉自动缠绕过程的力学模型，以深入分析缠绕机理。接着，通过有限元动力学仿真研究了缠绕张力和电堆转速对保温棉缠绕效果的影响，并将仿真结果导入数字孪生系统，以优化数字孪生结构层和控制层程序。最后，通过联合调试成功实现了保温棉缠绕自动化并生产出包覆效果良好的热电池电堆。所采用的研究方法有效地提高了研发效率、加速了设计过程以及降低了试错成本，可为缠绕包装自动化装配研究提供参考。


关键词： 自动缠绕系统,  缠绕机理,  数字孪生,  有限元动力学仿真 
Fig.1 Digital twin mapping structure model of automatic insulation cotton winding device
Fig.2 Architecture of automatic winding digital twin system for insulation cotton
Fig.3 Data type conversion of virtual position sensor
Fig.4 NetToPLCsim connecting interface
Fig.5 Signal creation interface of KEPServerEX platform
Fig.6 Signal mapping between PLC and NX MCD software
Fig.7 Force analysis diagram of automatic insulation cotton winding process
材料

密度/

(g/m3)

杨氏模量/MPa泊松比
金属（电堆）0.882 1000.31
玻璃纤维（棉条）0.112800.40
聚酰亚胺薄膜（胶带）1.425400.37
Table 1 Material mechanics parameters of stack, tampon and tape
Fig.8 Load and constraint of finite element simulation model of automatic insulation cotton winding process
Fig.9 Strain cloud map of tape during automatic winding process of insulation cotton
Fig.10 Change curve of tape strain with winding tension under different stack rotation speeds
Fig.11 Test site of automatic winding digital twin system for insulation cotton
Fig.12 Virtual and real mapping and data transmission of automatic insulation cotton winding process
Fig.13 Comparison of winding effect of insulation cotton
实验条件（电动转速和摩擦力矩）组别
123
90 (°)/s和小摩擦力矩5.55.55.7
90 (°)/s和大摩擦力矩7.37.07.5
120 (°)/s和小摩擦力矩5.54.17.3
120 (°)/s和大摩擦力矩6.58.06.3
Table 2 Maximum peeling force of tape
[1]   陆瑞生.热电池［M］.北京：国防工业出版社，2005：82.
LU R S. Thermal battery［M］. Beijing： National Defense Industry Press， 2005： 82.
[2]   崔烘槊.热电池自动装配技术的研究［D］.沈阳：沈阳理工大学，2020.
CUI H S. Research on automatic assembly technology of thermal battery［D］. Shenyang： Shenyang Ligong University， 2020.
[3]   张嘉易，崔烘槊，郝永平，等.一种热电池自动缠绕过程的运动分析［J］.一重技术，2020（5）：13-16. doi：10.3969/j.issn.1673-3355.2020.05.004
ZHANG J Y， CUI H S， HAO Y P， et al. Dynamic analysis of automatic winding process for thermal batteries［J］. CFHI Technology， 2020（5）： 13-16.
doi: 10.3969/j.issn.1673-3355.2020.05.004
[4]   张月，方成刚.飞灰包装智能产线设计与虚拟调试［J］.包装工程，2022，43（11）：226-235.
ZHANG Y， FANG C G. Design and virtual commissioning of intelligent production line of ash packaging［J］. Packaging Engineering， 2022， 43（11）： 226-235.
[5]   王剑，王好臣，李学伟，等. 基于OPC UA的数字孪生车间信息物理融合系统［J］.现代制造工程，2023（4）：43-50.
WANG J， WANG H C， LI X W， et al. Digital twin workshop information physical fusion system based on OPC UA［J］. Modern Manufacturing Engineering， 2023（4）： 43-50.
[6]   傅贵武，王兴波，田英.基于五轴加工中心智能生产线的数字孪生应用研究［J］.工程设计学报，2021，28（4）：426-432. doi：10.3785/j.issn.1006-754X.2021.00.051
FU G W， WANG X B， TIAN Y. Research on application of digital twin based on intelligent production line of five-axis machining center［J］. Chinese Journal of Engineering Design， 2021， 28（4）： 426-432.
doi: 10.3785/j.issn.1006-754X.2021.00.051
[7]   高丹，朱翔，韩永成，等.基于云平台的数字孪生多适应装配产线设计［J］.组合机床与自动化加工技术，2021（6）：122-126.
GAO D， ZHU X， HAN Y C， et al. Design of digital twin multi adaptive assembly line based on cloud platform［J］. Modular Machine Tool & Automatic Manufacturing Technique， 2021（6）： 122-126.
[8]   WANG J， DAI C， SHI K， et al. Research on rigid body motion tracing in space based on NX MCD［J］. IOP Conference Series： Materials Science and Engineering， 2018， 320： 012012.
[9]   周军，刘占强，邓建新，等.生产线虚拟仿真设计研究［J］.现代制造工程，2004（12）：81-83. doi：10.3321/j.issn:1003-8728.2004.05.024
ZHOU J， LIU Z Q， DENG J X， et al. Virtual simulation & design of production line［J］. Modern Manufacturing Engineering， 2004（12）： 81-83.
doi: 10.3321/j.issn:1003-8728.2004.05.024
[10]   严惠，邓小龙，李志远，等.基于数字孪生的FMS运维监控系统设计与研究［J］.制造业自动化，2021，43（10）：122-126. doi：10.3969/j.issn.1009-0134.2021.10.028
YAN H， DENG X L， LI Z Y， et al. Design and research of FMS operation and maintenance monitoring system based on digital twin［J］. Manufacturing Automation， 2021， 43（10）： 122-126.
doi: 10.3969/j.issn.1009-0134.2021.10.028
[11]   戴璐，邵一夫，郭宇元，等.基于数字孪生的卫星装备智 能设计系统［J］.兵工学报，2022，43（）：139-145.
DAI L， SHAO Y F， GUO Y Y， et al. Intelligent design system of satellite equipment based on digital twins［J］. Acta Armamentarii， 2022， 43（）： 139-145.
[12]   孙明波，安彬，汪洪波，等.超燃冲压发动机仿真：从数值飞行到数智飞行［J］.力学学报，2022，54（3）：588-600.
SUN M B， AN B， WANG H B， et al. Numerical simulation of the scramjet engine： from numerical flight to intelligent numerical flight［J］. Chinese Journal of Theoretical and Applied Mechanics， 2022， 54（3）： 588-600.
[13]   廉继杰.绝热层缠绕成型运动分析及缠绕速度控制［D］.大连：大连理工大学，2022.
LIAN J J. Motion analysis and winding speed control of heat insulation winding molding［D］. Dalian： Dalian University of Technology， 2022.
[14]   潘浩东，王瑞，舒慧明，等.一体化包覆药柱缠绕应力的数值计算［J］.固体火箭技术，2021，44（4）：498-505. doi：10.7673/j.issn.1006
PAN H D， WANG R， SHU H M， et al. Numerical calculation of winding stress of an integrated coated propellant grain［J］. Journal of Solid Rocket Technology， 2021， 44（4）： 498-505.
doi: 10.7673/j.issn.1006
[15]   蒋建东，章恩光，赵颖娣，等.盾构刀盘振动掘削动力学建模与仿真研究［J］.机械工程学报，2019，55（5）：113-120. doi：10.3901/jme.2019.05.113
JIANG J D， ZHANG E G， ZHAO Y D， et al. Dynamic modeling and simulation of shield tunneling cutter-head in oscillatory excavation［J］. Journal of Mechanical Engineering， 2019， 55（5）： 113-120.
doi: 10.3901/jme.2019.05.113
[16]   SI Y W， ZHANG L L， DU Y P， et al. A new starting curve based on acceleration and deceleration theory of stepping motor［J］. Journal of Physics： Conference Series， 2020， 1549（4）： 042016.
[17]   杨亮亮，许守金，史伟民，等.始末速度不为零的S型加减速时间规划算法研究［J］.机械工程学报，2016，52（23）：199-206. doi：10.3901/jme.2016.23.199
YANG L L， XU S J， SHI W M， et al. Research on S type acceleration and deceleration time planning algorithm with beginning and end speed non-zero［J］. Journal of Mechanical Engineering， 2016， 52（23）： 199-206.
doi: 10.3901/jme.2016.23.199
[18]   AFOLALU S A， IKUMAPAYI O M， ABDULKAREEM A， et al. Enviable roles of manufacturing processes in sustainable fourth industrial revolution： a case study of mechatronics［J］. Materials Today： Proceedings， 2021， 44（Part 1）： 2895-2901.
[19]   PINTOR N A J， MANCILLA C A M， OSUNA G A H， et al. Design， implementation， and control of a linear electric actuator for educational mechatronics［J］. Machines， 2023， 11（9）： 894.
[1] 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[J]. Chinese Journal of Engineering Design, 2023, 30(4): 409-418.
[2] Zhe XU,Shufeng SUN,Xingbo ZHANG,Xi WANG,Fengyun ZHANG,Pingping WANG,Zhangwei XIE,Yu ZHANG,Jixin LIU,Weili SUN,Aixia CAO. Interactive control system of optical displacement stage based on digital twin[J]. Chinese Journal of Engineering Design, 2023, 30(2): 254-261.
[3] Xu-hui ZHANG,Jia-shan JU,Wen-juan YANG,Xin-yuan Lü. Predictive maintenance system for complex mining equipment based on digital twin[J]. Chinese Journal of Engineering Design, 2022, 29(5): 643-650.
[4] FU Gui-wu, WANG Xing-bo, TIAN Ying. Research on application of digital twin based on intelligent production line of five-axis machining center[J]. Chinese Journal of Engineering Design, 2021, 28(4): 426-432.
[5] BAI Zhong-hang, SUN Yi-wei, XU Tong, DING Man. Construction of product digital twin model based on design task in conceptual design[J]. Chinese Journal of Engineering Design, 2020, 27(6): 681-689.
[6] WANG An-bang, SUN Wen-bin, DUAN Guo-lin. Research on intelligent method of manufacturing and processing equipment based on digital twin and deep learning technology[J]. Chinese Journal of Engineering Design, 2019, 26(6): 666-674.