基于五维模型理论的码垛工作站数字孪生系统

王法勇^1,2，赵凌燕^1*，张洁洁²，焦培刚¹

1.山东交通学院工程机械学院，山东 济南  250357；2.合肥哈工热气球数字科技有限公司，安徽 合肥  230601

摘要：为提高码垛工作站的智能化水平，以数字孪生五维模型理论为基础，采用三维建模软件SolidWorks对物理码垛工作站进行三维建模，通过仿真软件Simreal将三维模型转化为虚拟码垛工作站，设置虚拟码垛工作站中六轴工业机械臂、气动吸盘、传感器等结构的物理属性和初始参数，采用可编程逻辑控制器设计并实现码垛工作站的工艺流程，通过通信协议Modbus、Siemens S7等实现物理码垛工作站与虚拟码垛工作站间的数据交互和实时通信，构建码垛工作站的数字孪生系统。开展试验测试码垛数字孪生系统功能，在线可视化监测系统运行工作状态，验证数据传输的准确性和实时性。结果表明：所构建的码垛数字孪生系统可同步映射实体码垛工作站的动作，统计码垛过程中的产能等数据，物料放置的准确率达99%以上，避免错位现象发生。

关键词：数字孪生；五维模型；码垛工作站；通信协议

Digital twin system of stacking workstation based on five-dimensional model theory

WANG Fayong^1,2, ZHAO Lingyan^1*, ZHANG Jiejie², JIAO Peigang¹

1.School of Construction Machinery, Shandong Jiaotong University, Jinan 250357, China;

2.Hefei Hagong Balloon Digital Technology Co., Ltd., Hefei 230601, China

Abstract:To improve the intelligence level of the palletizing workstation, based on the five-dimensional model theory of digital twins, SolidWorks 3D modeling software is used to create a three-dimensional model of the physical palletizing workstation. The 3D model is transformed into a virtual palletizing workstation using the simulation software Simreal. The physical properties and initial parameters of the six-axis industrial robotic arm, pneumatic suction cup, sensors, and other mechanisms in the virtual palletizing workstation are set. A programmable logic controller is used to design and implement the process flow of the palletizing workstation. Data interaction and real-time communication between the physical and virtual palletizing workstations are achieved through communication protocols such as Modbus and Siemens S7, constructing a digital twin system for the palletizing workstation. Experimental tests are conducted to validate the functionality of the palletizing digital twin system, with online visual monitoring of the system′s operational status and verification of data transmission accuracy and real-time performance. Research shows that the constructed palletizing digital twin system can synchronously map the actions of the physical palletizing workstation, collect data such as productivity during the palletizing process, improve the accuracy of material placement to over 99%, and prevent misalignment occurrences.

Keywords:digital twin; five-dimensional model; palletizing workstation; communication protocol