基于混合模型的虚拟装配关键技术研究

针对虚拟装配中采用多边形网格模型引起的组件定位困难和碰撞检测精度低等问题,提出一种采用精确几何模型及其对应的多边形网格模型的混合模型作为底层数据,支持精确装配的虚拟装配系统构造方法,并基于Parasolid和Vir-tools平台进行了实现。基于混合模型的碰撞检测能根据计算精度和时间要求自适应求解,在速度快的同时,满足高精度碰撞检测要求;基于混合模型的组件装配,采用离散采样点定义装配路径,通过装配几何约束交互式定义限制组件的运动范围,通过自由度规约、装配约束求解实现了零部件精确定位,通过四元数插值实现装配路径中零部件位姿的平滑过渡,能满足高精度的装配要求。该方法已经在开发的多个系统中得到验证和应用。     

Qualitative behavioral reasoning from components’ interfaces to components’ functions for DMU adaption to FE analyses

A digital mock-up (DMU), with its B-Rep model of product components, is a standard industrial representation that lacks geometric information about interfaces between components. Component shapes reflect common engineering practices that influence component interfaces with interferences and not only contacts.The proposed approach builds upon relationships between function, behavior, and shape to derive functional information from the geometry of component interfaces. Among these concepts, the concept of behavior is more difficult to set up and connect to the geometry of interfaces and functions. Indeed, states and design rules are introduced to express the behavior of components through a qualitative reasoning process. This reasoning process, in turn, takes advantage of domain knowledge rules and facts, checking the validity of certain hypotheses that must hold true all along a specific state of the product’s lifecycle, such as operational, stand-by or relaxed states. Eliminating configurations that contradict one or more of those hypotheses in their corresponding reference state reduces ambiguity, subsequently producing functional information in a bottom-up manner.This bottom-up process starts with the generation of a conventional interfaces graph (CIG) with components as nodes, and conventional interfaces (CIs) as arcs. A CI is initially defined by a geometric interaction that can be a contact or an interference between two components. CIs are then populated with functional interpretations (FIs) according to their geometric properties, producing potentially many combinations. A first step of the reasoning process, the validation against reference states, reduces the number of FIs per CI.Domain knowledge rules are then applied again to group semantics of component interfaces into one functional designation per component to connect together geometric entities of its boundary with its function.     

From simple digital twin to complex digital twin Part I: A novel modeling method for multi-scale and multi-scenario digital twin

In recent years, the digital twin has attracted widespread attention as an important means of digitalization and intelligence. However, the digital twin is becoming more and more complex due to the expansion of need on the simulation of multi-scale and multi-scenario in reality. The instance of digital twin in references mostly concentrates a particular application, while it is still a lack of a method for constructing the complex digital twin in the total elements, the variable scale of working environments, changeable process, not even the coupling effects. In this paper, a novel modeling method for such a complex digital twin is proposed based on the standardized processing on the model division and assembly. Firstly, the complex model of digital twin is divided into several simple models according to the composition, context, component, and code in 4C architecture. Composition and context make the digital twin focus on the effective elements in a specific scale and scenario. Component and code develop the digital twin in standard-based modularization. Secondly, assemble the simple models of digital twins into the complex model through information fusion, multi-scale association and multi-scenarios iterations. Ontology establishes the complete information library of the entities on different digital twins. Knowledge graph bridges the structure relationship between the different scales of digital twins. The scenario iterations realize the behavior interaction and the accuracy calculation results. It provides an implementable method to construct a complex model of digital twin, and the reuse of components and code also enables rapid development of digital twins.     

Virtual reality for assembly methods prototyping: a review

Assembly planning and evaluation is an important component of the product design process in which details about how parts of a new product will be put together are formalized. A well designed assembly process should take into account various factors such as optimum assembly time and sequence, tooling and fixture requirements, ergonomics, operator safety, and accessibility, among others. Existing computer-based tools to support virtual assembly either concentrate solely on representation of the geometry of parts and fixtures and evaluation of clearances and tolerances or use simulated human mannequins to approximate human interaction in the assembly process. Virtual reality technology has the potential to support integration of natural human motions into the computer aided assembly planning environment (Ritchie et al. in Proc I MECH E Part B J Eng 213(5):461–474, 1999). This would allow evaluations of an assembler’s ability to manipulate and assemble parts and result in reduced time and cost for product design. This paper provides a review of the research in virtual assembly and categorizes the different approaches. Finally, critical requirements and directions for future research are presented.     

Feature-based modeling for industrial processes in the context of digital twins: A case study of HVOF process

Industrial process modeling is currently undergoing a fundamental transformation, leading towards interconnected close-loop twins of models, i.e., the parametrically-controlled real-world physics model, and its corresponding digitalized virtual system model. Between these models, a highly time-sensitive mutual validation mechanism and a coherent and consistent control strategy are applied, which demand complex virtual-and-real world model-based information mapping and synchronization. Thus, this research proposes a semantic conceptual framework for industrial process modeling in the context of digital twins. Based on a hierarchical structure of digital twins, this framework modularizes the modeling process in terms of the semantic information modules of physics in the real-world phenomena, and clarifies inter-module associations and near-real-time data transmission coupled with virtual analysis in CAE environment so that the time-sensitive phenomenon information objects distributed on virtually-separated sub-level physics models can be supported for representing the real-world process comprehensively. Advanced feature concept is adopted to construct the digital models as the basic compositions of any virtual industrial process. The related feature definitions are extended in this work so that the common characteristics in the concept of digital twins could be generically and concisely represented. To validate the modeling method, the digital model of a prototyped High-velocity Oxygen-fuel (HVOF) coating process system was constructed as the case study. The data from the nozzle trajectory, the flame, and the in-flight particle behavior, and the transient thermal performance of the coating layer and substrate were synchronously incorporated for simulating the transient phenomena of the substrate component temperature and coating thickness distribution on the substrate surface. The final simulation result validates that the feature-based digital model is able to comprehensively reflect the real-world scenario on the virtual side. To illustrate how the developed model provides meaningful feedback to the real-world control, a general digital twin setup of the model is given at the end of the case study.     

基于循环迭代的飞机虚拟拆装过程建模方法

将循环迭代法应用于飞机虚拟拆装,研究飞机的拆装过程,提出一种基于循环迭代的虚拟拆装过程建模方法。结合飞机拆装过程动态循环的特性和虚拟人拆装行为并行相似的特点,建立虚拟人拆装行为参数化模型,规范虚拟人拆装行为的统一表达;在此基础上,分析虚拟人与部件的交互关系,构造虚拟人拆装行为、拆装次序、部件状态之间的迭代函数,建立虚拟拆装过程模型,实现虚拟人拆装行为的参数化描述和部件拆装过程的表达。以分布式虚拟维修训练平台中的集中故障显示接口组件拆装为例,对该方法进行仿真验证和比对,结果表明,以虚拟人拆装行为变化表示的部件状态变化使部件的拆装更易于表达,拆装训练效率有所提高。     

面向虚拟装配的产品公差混合建模技术

为实现带公差的虚拟装配,应首先解决产品建模问题.通过分析虚拟装配对产品公差模型的要求,提出了虚拟环境下产品公差混合模型.该模型将产品基本公差信息与附加公差信息相结合,将普通几何拓扑信息与精确几何信息相关联,同时添加了装配特征等工程语义信息;详细阐述了产品公差混合模型的层次结构、模型信息来源、各个层次之间的映射方法及精度信息的表达方式;最后介绍了该模型的应用.     

基于Web的三维协同设计模型及其关键技术

为在虚拟环境下进行产品异地实时设计和装配,提出一种基于Web的三维协同设计模型.该模型使用户既可以通过浏览器在客户端的虚拟场景中进行个性化设计,也可以与其他用户进行协同设计.通过详细分析协同设计过程,研究任意形状基本实体的表征、零件扩展属性的描述、基本操作的表示、零件之间装配关系和部件运动仿真属性等的建立.基于ACIS和ECSG的三维造型技术和层次细节模型的生成算法,研发以某产品为对象的原型系统,证实该三维协同设计模型的可行性和先进性.     

层次化单元装配模型

装配设计是产品设计的重要设计阶段,在分析装配设计和层次化单元任务模型的基础上,建立了支持装配设计的面向对象的层次化单元装配模型。装配单元的层次化结构表达了功能结构,通过功能映射可以建立功能到单元的对应关系。研究了基于层次化装配单元模型的装配设计,讨论了支持装配设计的开发的单元库分级管理策略。     

Tele-immersive product evaluation: a review and an implementation framework

A novel virtual tele-immersive product evaluation environment is conceived. The components for the tele-immersive virtual environment for product evaluation include a robust virtual reality (VR) hardware system, associated VR driving software, development tool for the tele-immersive virtual environment, networking software, user representation scheme and tools for developing 3D models and incorporating dynamic properties into the models. We have developed a model to allow users to collaboratively evaluate products using the CAVE^TM, Performer, CAVERN, CAVEActors, Pro/ENGINEER, and ADAMS.     

Quantitative measurement of component accessibility and product assemblability for design for assembly application

One of the important issues about product assemblability (PA) is to design a product configuration that will facilitate assembly operations. The product configuration in this paper means the arrangement of components within a product. When a product is assembled, every component has to be handled by an assembly agent from the feeding position to the composing position. During this action, the product configuration plays a critical role in the planning and execution of the handling task of each component. The influence of the product configuration on the accessible range of a component can be investigated by considering the accessibility of the component. With an assembly oriented product configuration a product can achieve maximal assemblability in terms of the accessibility of each component.A quantitative rating, referred to as component accessibility (CA), has been developed to measure the accessibility of a component of a product during the conceptual and preliminary design stages. The CA is defined as the reciprocal of the information required for an ideal assembly agent to manipulate the component to have collision-free straight-line destination approaching in the presence of other assembled components. This CA has not previously been quantified and thus designers have only been able to rely on their own experience in arranging the components of a product. With the help of CA, a designer can select an optimal arrangement of components for assembly operations, and the best method for joining mating components can be chosen accordingly. As a result of the provision of CA, traditional DFA evaluation methodologies can be reinforced and many DFA-related applications can be further explored.Another quantitative measure, referred to as PA, has been developed accordingly to quantify the assemblability of a product on the basis of accessibility of each component. The relationship between the information content of assembling a product and the information content associated with each component has been derived. It has been found that the relationship between PA and CA of each component is similar to the relationship between the resistance of an equivalent resistor and the resistance of parallel resistors in electricity.     

基于多智能体的数字孪生及其在工业中应用的综述

数字孪生是一种将物理实体数字化的技术,通过建立虚拟的数字孪生模型模拟实际的物理过程,以便进行模拟仿真、数据分析和优化设计等操作.鉴于此,分析数字孪生技术在复杂工业生产中的发展历程和研究现状,并重点讨论其概念、国家相关重点研究的政策,以及数字孪生使能技术在各行业的应用.主要途径是分析和综述基于多智能体的数字孪生、基于数字孪生的设计、制造和运维、数字孪生的集成在智能制造中的应用相关的研究成果.此外,提出高炉连续生产数字孪生方案和大飞机多智能体离散制造方案,高炉模型包括成分场大模型和增量学习小模型,该模型可以为数字孪生在复杂流程工业中的应用提供带有增量补偿的机理与计算机视觉相结合的解决方案.在复杂工业制造中,数字孪生和多智能体技术可以提高生产效率和质量,减少能源消耗和废品产生,同时也能够降低复杂度、安全风险和成本.     

基于语义的虚拟装配仿真模型研究及应用

针对虚拟装配中装配模型的信息完备性与虚拟仿真系统的交互效率之间的矛盾,提出一种轻量化的基于树-图分离结构的虚拟装配模型,该模型包括装配树模型和语义关系图模型。装配树模型以二叉树的形式表达虚拟产品的层次结构以及零部件间的装配顺序,语义关系图以二分图的形式表达零件之间的装配关系。将该模型应用于水轮机组虚拟装配仿真系统中,不仅满足了虚拟仿真过程对装配模型信息表达的要求,而且减少了系统存储负担,提高了交互效率。     

Digital twin-based smart assembly process design and application framework for complex products and its case study

With rapid advances in new generation information technologies, digital twin (DT), and cyber-physical system, smart assembly has become a core focus for intelligent manufacturing in the fourth industrial evolution. Deep integration between information and physical worlds is a key phase to develop smart assembly process design that bridge the gap between product assembly design and manufacturing. This paper presents a digital twin reference model for smart assembly process design, and proposes an application framework for DT-based smart assembly with three layers. Product assembly station components are detailed in the physical space layer; two main modules, communication connection and data processing, are introduced in the interaction layer; and we discuss working mechanisms of assembly process planning, simulation, predication, and control management in the virtual space layer in detail. A case study shows the proposed approach application for an experimental simplified satellite assembly case using the DT-based assembly application system (DT-AAS) to verify the proposed application framework and method effectiveness.     

Automatically generating assembly tolerance types with an ontology-based approach

In most cases, designers have to manually specify both assembly tolerance types and values when they design a mechanical product. Different designers will possibly specify different assembly tolerance types and values for the same nominal geometry. Furthermore, assembly tolerance specification design of a complex product is a highly collaborative process, in which semantic interoperability issues significantly arise. These situations will cause the uncertainty in assembly tolerance specification design and finally affect the quality of the product. In order to reduce the uncertainty and to support the semantic interoperability in assembly tolerance specification design, an ontology-based approach for automatically generating assembly tolerance types is proposed. First of all, an extended assembly tolerance representation model is constructed by introducing a spatial relation layer. The constructed model is hierarchically organized and consists of part layer, assembly feature surface layer, and spatial relation layer. All these layers are defined with Web Ontology Language (OWL) assertions. Next, a meta-ontology for assembly tolerance representations is constructed. With this meta-ontology, the domain-specific assembly tolerance representation knowledge can be derived by reusing or inheriting the classes or properties. Based on this, assembly tolerance representation knowledge is formalized using OWL. As a result, assembly tolerance representation knowledge has well-defined semantics due to the logic-based semantics of OWL, making it possible to automatically detect inconsistencies of assembly tolerance representation knowledge bases. The mapping relations between spatial relations and assembly tolerance types are represented in Semantic Web Rule Language (SWRL). Furthermore, actual generation processes of assembly tolerance types are carried out using Java Expert System Shell (JESS) by mapping OWL-based structure knowledge and SWRL-based constraint knowledge into JESS facts and JESS rules, respectively. Based on this, an approach for automatically generating assembly tolerance types is proposed. Finally, the effectiveness of the proposed approach is demonstrated by a practical example.     

Digital twins for collaborative robots: A case study in human-robot interaction

Human-robot collaboration (HRC) can expand the level of automation in areas that have conventionally been difficult to automate such as assembly. However, the need of adaptability and the dynamics of human presence are keeping the full potential of human-robot collaborative systems difficult to achieve. This paper explores the opportunities of using a digital twin to address the complexity of collaborative production systems through an industrial case and a demonstrator. A digital twin, as a virtual counterpart of a physical human-robot assembly system, is built as a ‘front-runner’ for validation and control throughout its design, build and operation. The forms of digital twins along system's life cycle, its building blocks and the potential advantages are presented and discussed. Recommendations for future research and practice in the use of digital twins in the field of cobotics are given.     

An economic manufacturing quantity model for a two-stage assembly system with imperfect processes and variable production rate

This article considers a two-stage assembly system with imperfect processes. The former is an automatic stage in which the required components are manufactured. The latter is a manual stage which deals with taking the components to assemble the end product. In addition, the component processes are independent of each other, and the assembly rate is variable. Shortage is allowed, and the unsatisfied demand is completely backlogged. Then, we formulate the proposed problem as a cost minimization model where the assembly rate and the production run time of each component process are decision variables. An algorithm for the computations of the optimal solutions under the constraint of assembly rate is also provided. Finally, a numerical example and sensitivity analysis are carried out to illustrate the model.     

Feature-based assembly modeling and sequence generation

A feature-based model is proposed for assembly sequence planning automation. The fundamental assembly modeling strategy for a product is based on the mating features of its components. The objectives of this study are to integrate assembly planning of a product with its CAD model, generate a correct and practical assembly sequence and establish a software system to carry out the planning process. A disassembly approach in assembly planning is used in this study. The degree of freedom information between two mating features is used to characterize their kinematic conditions. Boolean operations of the degrees of freedom on all features of a component provides its local degree of freedom, which is used to set up the functional precedence relation. In some cases, where the functional precedence relation cannot be detected by geometric reasoning, clipping of the known `common sense' relation is applied by a user. A bounding box checking approach is used to ensure no global collision during assembly. Furthermore, a set of criteria based on assembly feasibility, manipulability, assembly direction, cost and stability is used to choose a good assembly sequence.     

Multiple-view feature modelling for integral product development

To allow a designer to focus on the information that is relevant for a particular product development phase, is an important aspect of integral product development. Unlike current modelling systems, multiple-view feature modelling can adequately support this, by providing an own view on a product for each phase. Each view contains a feature model of the product specific for the corresponding phase. An approach to multiple-view feature modelling is presented that supports conceptual design, assembly design, part detail design and part manufacturing planning. It does not only provide views with form features to model single parts, as previous approaches to multiple-view feature modelling did, but also a view with conceptual features, to model the product configuration with functional components and interfaces between these components, and a view with assembly features, to model the connections between components. The general concept of this multiple-view feature modelling approach, the functionality of the four views, and the way the views are kept consistent, are described.     

From simple digital twin to complex digital twin part II: Multi-scenario applications of digital twin shop floor

The shop floor has always been an important application object for the digital twin. It is well known that production, process, and product are the core business of the shop floor. Therefore, the digital twin shop floor covers multi-dimensional information and multi-scale application scenarios. In this paper, the digital twin shop floor is constructed according to the modeling method of the complex digital twin proposed in Part I. The digital twin shop floor is firstly divided into several simple digital twins that focus on scenarios of different scales. Two simple application scenarios are constructed, including tool wear prediction and spindle temperature prediction. Main functions in different application scenarios, such as data acquisition, data processing, and data visualization, are implemented and encapsulated as components to construct simple digital twins. Secondly, ontology models, knowledge graphs, and message queues are used to assemble these simple digital twins into the complex digital twin shop floor. And two complex application scenarios are constructed, including machining geometry simulation considering spindle temperature and production scheduling considering tool wear. The implementation of the complex digital twin shop floor demonstrates the feasibility of the proposed modeling method.