Key Technology Research On Distributed Simulation And Virtual Monitoring Of Manufacturing System

Manufacturing industry is always playing an important foundation for the development of the national economy.And the development of manufacturing industry depends on the progress of manufacturing technology.However,the development of manufacturing industry could not be separated from the support of information data.And computer simulation and monitoring is the main way to get a variety of data at present.So the research about simulation and monitoring has been an important issue in the field of manufacture.At present,the object of computer simulation in the field of manufacture is mostly a single device due to the limitation of computing resources.However,the manufacturing system has become the main manufacturing mode.And it is necessary to simulate the whole manufacturing system.In recent years,with the technology development of network,computer simulation,virtual reality and virtual manufacturing,it has been able to establish a real time distributed interactive simulation system with powerful computing capability.For a long time,the Human-Machine Interaction(HMI)of the monitoring as an important way to get data is usually constituted of chart,2D interface,audio,video,etc.However,the sense of reality and interaction of graphics and 2D interface is not intuitionistic and intelligible.And the transmitted data sizes of video and audio are too large to benefit of information communication.Therefore,it is necessary to seek a monitoring form which has a direct-viewing and friendly interactive interface.And its transmitted data sizes are far less than video or audio.Therefore,such a monitoring form is the development trend of monitoring system.The virtual monitoring based on virtual environment is such a monitoring form.The most obvious feature of distributed interactive simulation and virtual monitoring of manufacturing system,which is that they are based on virtual environment,can be found through analyzing their development trend.Therefore,the key technology of distributed interactive simulation and virtual monitoring of manufacturing system has been researched in this thesis.The main research work in this thesis is as follows.(1)The function requirements of the distributed simulation and virtual monitoring of a basic manufacturing cell,which will be realized in this thesis,are analyzed.Then,the system architecture corresponding with the function requirements is designed according to the distributed standards named as IEEE 1516e and the Agent technology.And the networking protocol and communication model used for the distributed simulation and virtual monitoring are selected.(2)In order to realize the distributed interactive simulation and virtual monitoring of a manufacturing system,the visual simulation environment and virtual monitoring of a machine tool are researched further.The kinematic models of a machine tool named as DMG-DMU50 are established.And the correctness of the models is verified.Then,the material removal algorithm based on the computation capability of GPU,which will be used for simulating the machining process of a machine tool,is proposed to ensure rendering the virtual environment real tne.The algorithm of compiling the NC codes is also researched further.According to these algorithms,the material removal simulation of machining process is realized.The method simulating the material removal is validated through comparing with the simulation results based on Vericut.The class diagram of visual environment of a five-axis machine tool,class diagram of the entity controlling simulation and class diagram of the agent managing the monitoring process are designed according to the above research to facilitate developing and realizing the simulation and monitoring of a machine tool in a manufacturing system.(3)In order to integrate the milling force simulation of a ball-end milling cutter into the distributed simulation system of a manufacturing systen,the milling force models being applicable to multi-axis milling are derived according to the basic theory models of milling force.And the method,how to solve the integral boundary conditions of the milling force models with the simulation of material removal,has been discussed further.The identification models for milling force coefficients have also been derived from the milling force models.The above research has been validated through some experiments.After finish the above work,the class diagram of the milling force simulation entity was designed to facilitate developing and realizing the milling force simulation function in the distributed simulation system for a manufacturing system.(4)In order to realize the simulation entity and monitoring agent for 6R industrial robot,the kinematic models of a 6R industrial robot are modelled firstly.Then,the analytical solutions of the inverse kinematic models are derived.And their correctness is validated by some experiments.The simulation entity of the 6R industrial robot is designed and the core modules are developed,based on the analysis of robot control commands,the establishment of the Jacobi matrix and the design of the control instruction of the compilation process.To realize the monitoring agent of the robot,the monitor communication interface of robot is studied further.The class diagram of monitoring agent is designed.And the core modules are developed based on the Network communication development kit,named as JOpenShowVar.(5)In order to get movement data for virtual monitoring,a movement measurement method based on vision is studied further.Taking the Kinect as the sensor node,the system architecture of measuring movement is designed based on the basic architecture of Cyber-Physical System(CPS).The fusion theory of the depth image and color image from Kinect,which is used for calculating the coordinate values of the tracking object,is researched further.Then,the key modules of the theory are developed.And the correctness of the research is validated by some measuring and tracking experiments on the machine tool.(6)Based on the above theoretical research in this thesis and some free software development kits,a distributed simulation and virtual monitoring system for a manufacturing system is developed according to the designed class diagrams in each chapter.And the experiments of running the developed system tentatively show that the theoretical research and developed programs in the thesis are correct and reliable.