Preface
At present, China has entered the "technology + application" digital twin dual-drive era. Driven by market demand and national policies, various localities have developed digital twin technology according to local conditions and carried out in-depth digital twin application construction. Today we will focus on the application of digital twin technology in factories. We hope that through the in-depth analysis and results sharing of this case, we can provide reference and reference for the application of digital twin technology in thousands of industries.
1. Why build a digital twin factory
With the advancement of the national new infrastructure policy, the new generation of information technology represented by 5G, IoT, cloud computing, big data, and artificial intelligence is booming and promoting the transformation of urban management to digital, networked, and intelligent. 3D visualization combined with cloud computing data analysis and Internet of Things technology is integrated into the digital twin, and has gradually extended to urban, transportation, industrial and other application fields.
In the field of industrial production, in 2021, the Ministry of Industry and Information Technology issued the "14th Five-Year Plan for the Deep Integration of Informatization and Industrialization Development Plan" and the "14th Five-Year Plan" for Intelligent Manufacturing Development Plan. The plan clearly stated that by 2025, informatization and industrialization will achieve integrated development on a wider, deeper, and higher level. The new generation of information technology will accelerate penetration into various fields of manufacturing, and the pace of digital transformation in manufacturing will be significantly accelerated. By 2025, most of the manufacturing enterprises above designated size will realize digitalization and networking, and backbone enterprises in key industries will initially apply intelligence;
Driven by technology updates and national policies, digital twin technology has become the darling of production in the industrial field and continues to flourish.
Image source: Yizhiwei Digital Twin World White Paper 2023
2. How to build a digital twin factory?
——Taking the operation and management system construction of a digital twin smart factory in Digital Twin Cloud as an example:
(1) Construction background:
Traditional manufacturing enterprises are facing multiple difficulties, such as the reduction of demographic dividends, rising labor costs; rising raw material costs, reduced profits; low efficiency , low production efficiency, declining product quality, difficult quality control management; slow channel information transmission, backlog of inventory funds, etc. The only way to break through the encirclement is to carry out digital transformation. With the introduction of the Smart Factory Made in China 2025 strategy, more and more manufacturing companies have begun to transform into smart factories. Under the current upsurge of Industry 4.0, Industrial Internet, Internet of Things, and digital twins, it provides a good technical support for transformation.
(2) Solution
The digital twin smart factory operation and management system independently developed by Digital Twins Cloud uses oblique photography, BIM and other data to carry out refined 1:1 3D modeling of the overall appearance of the factory area and production lines to create a factory workshop scene display and process A comprehensive management platform integrating process display, comprehensive map management, personnel management, intelligent transportation management, monitoring management, alarm management, equipment management, and inventory management. Integrate factory platform data to provide factory operation management services with all elements, all scenarios, and full cycles for the factory floor. Achieve a one-screen overview of people, equipment, workshops, and factories, and one-click control. It is convenient for workshop managers to see the production and operation status and production operation data inside the workshop more clearly and intuitively, and it also provides guarantee for workshop managers to have a timely insight into the operation status of all equipment in the workshop, and can take corresponding measures in time when abnormalities occur .
Image source: EZ Micro Digital Twin World White Paper 2023
(1) Difficulty Analysis
The construction of the smart factory operation management system has the following difficulties:
First, data collection and modeling are difficult. The dimensions of data analysis in factories are relatively wide, including performance, production capacity, energy consumption, quality, and efficiency. There are many links involved in each dimension, and the difficulty of data collection and modeling is relatively high.
The second is the challenge of data governance. Because the data is scattered in each subsystem, the data caliber is inconsistent, the data granularity is coarse, and the update frequency is low. This leads to the problem that the data cannot be used, and it needs to be manually sorted or secondary processed before it can be used.
(2) Idea construction
Build a factory-level/workshop-level digital twin virtual control system, based on the virtual and real integration of digital twin virtual simulation and physical factory, to achieve visualization, real-time, operability and collaboration of workshop production management target expectations.
The project is mainly carried out around the following construction ideas:
1. Simulation of the production process. By simulating the production process, build a digital twin scene, especially for high-precision simulation of key production lines and technological processes. Based on the acquired real-time data, the virtual production line is driven and real-time business data is displayed to realize the equipment status and suggestions of the visualized production line.
Image source: Yizhiwei Digital Twin World White Paper 2023
2. Data integration and visualization. Taking the production line process or key equipment as a unit, the production data of the workshop is displayed by means of information panels, data labels, and data charts, so as to realize the visualization of production data and monitor production data in real time.
3. System operation platform construction. Through the combination of the factory operating environment and user needs, a set of platform requirements to support the normal operation of the system is built for users. Including overall overview browsing, production planning, inventory, transportation, equipment, energy consumption management and reverse control, etc., to help users actually solve production problems.
(3) Application construction
This project mainly focuses on the application construction of the following scenarios:
1. Twin overview of the production process
Through three-dimensional modeling of the entire factory area and various equipment and facilities in the workshop, the equipment layout and process are truly restored, and the workshop is realized The whole process of the internal production process is twinned, reaching the twinning levels of equipment level, module level and system level. Realistically reproduce the appearance, structure and operation details of equipment and facilities.
Image source: Yizhiwei Digital Twin World White Paper 2023
2. Multi-information system integration management
integrates and manages the information units provided by all different manufacturers in the workshop, collects data information of various frames in real time in the 3D twin factory, and integrates them into a unified Centralized display mode data access, management, and associated display analysis, realizes the management and control of "multiple information systems on one three-dimensional page", enables maintenance personnel to realize "management of multiple machines by one person" and breaks through isolated information islands, greatly improving work efficiency.
Image source: Yizhiwei Digital Twin World White Paper 2023
3. Production monitoring
Twin scenes and live video are compared and verified to assist in research and judgment. The live video is correlated and interacted with the intelligent analysis results. Real-time video intelligent association is carried out for production links and equipment where abnormalities and alarms occur, supporting security and safety production inspections, and realizing automatic video inspections.
Image source: EZ Micro Digital Twin World White Paper 2023
4. Inventory management
supports the integration of material and equipment management system data, real-time query of detailed information such as goods and equipment numbers, entry time, and inventory balance, from material and equipment procurement to production , The management and control of the entire life cycle of remaining inventory, assisting managers to improve the supervision of materials and equipment stacking sites, and reduce material and equipment management costs.
Image source: EZ Micro Digital Twin World White Paper 2023
5. Energy consumption management
is connected to the water, electricity, gas and other energy consumption subsystem data in the factory area to monitor the energy consumption situation in production and operation in real time. Perform multi-dimensional visual analysis of element indicators such as equipment operation and environmental monitoring, support energy consumption trend analysis and comprehensive evaluation of energy consumption indicators, help managers understand the energy consumption status of the plant area in real time, and provide a strong data basis for the rational allocation of resources, energy conservation and emission reduction in the plant area .
Image source: EZ Micro Digital Twin World White Paper 2023
6. Digital twin bidirectional control
Bidirectional transmission of production process data and command and control data between the digital twin factory and the physical entity factory, such as production equipment data, measuring instrument data, command and control data, etc. Correlation mapping and matching between physical factory and digital factory, command and control data realize system feedback for intelligent decision-making.
Image source: EZ Micro Digital Twin World White Paper 2023
(4) Construction achievements
The project mainly achieved the following achievements:
First, it is conducive to improving factory production efficiency, improving production quality, reducing enterprise costs, creating a safe production environment, and maintaining production. Sustainability;
the second is to help factory managers optimize and correct production problems through data integration and continuous analysis of various business systems; the third
is to help factory managers identify human, machine or environment and other factors. Improve production quality and production efficiency. Optimize production processes.
The fourth is to realize the optimization and independent control of the production process, and more importantly, to strengthen the leading position of the enterprise, thereby improving the competitiveness and innovation of the enterprise, and continuously promoting the development of the enterprise.
3. Summary
The empowerment of digital twins in the factory field can enable factories to reduce costs and increase efficiency, optimize production processes and management processes, and greatly promote the improvement of corporate status and strength. Digital twin technology is the core technology of future intelligent manufacturing, and it is a sharp weapon to realize the intelligent upgrading of manufacturing industry!
The above content comes from the "Digital Twin World White Paper (2023 Edition)"
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