Research On Simulation Of Production Process In Foundry Workshop Based On Digital Twin

The profit of foundry workshop is greatly affected by the output of casting,and the opacity of information flow and the obstruction of material flow are the main factors restricting the production.In order to improve the casting output and eliminate the adverse factors in the production process,the sand casting workshop was taken as the research object in this paper.In order to improve the casting output and eliminate the adverse factors in the production process,this paper takes the sand casting workshop as the research object,and puts forward the simulation framework of the production process of the foundry workshop based on digital twin with the help of the industrial Internet of things(IIo T)and the simulation technology combined with the value stream mapping analysis method.Through the real-time data acquisition and visual monitoring in the foundry workshop,the real-time update of the production process in the virtual workshop was realized.Through lean improvement and simulation optimization of production process in foundry workshop,real-time linkage between physical workshop and virtual workshop and continuous improvement of production process in physical workshop are realized.The main research results are as follows:Research on the production process of foundry workshop.Firstly,the material flow in foundry workshop was determined by analyzing the four stages of casting,cleaning,post-treatment and testing.Secondly,through analyzing the source and type of workshop data,the architecture of data acquisition and visual monitoring system of foundry workshop was constructed from four aspects: physical layer,conversion layer,adaptation layer and application layer.The middleware layer and heterogeneous device layer are further established,and the service contents of physical layer and heterogeneous device layer are specified.Finally,the constraints of process step constraint and Takt Time constraint are pointed out,and four optimization objectives are set,namely,to improve the balance rate of production line,to reduce the value-added time of products,to increase the value-added rate of products,and to increase the utilization rate of personnel and equipment.Real-time data acquisition and visual monitoring of foundry workshop.Aiming at the difficulties of heterogeneous equipment networking,real-time data acquisition and cross-platform data sharing in foundry workshop,the communication principle of industrial control signals among various heterogeneous equipment is studied in combination with relevant technologies and background knowledge of IIo T.A real-time data acquisition and visualization monitoring system of foundry workshop is designed and implemented from three aspects: data acquisition layer,data analysis layer and data service layer.The difficulty of communication between different communication protocols in industrial control is solved,and the interconnection between heterogeneous devices with different communication interfaces and different communication protocols is realized in the foundry workshop.The system provides data support services for the workshop,optimizes production plans,and reduces production costs.Finally,actual case verification was carried out.The data acquisition system is of great significance to the realization of heterogeneous equipment networking and automatic data acquisition and analysis in the process workshop,and it lays a data foundation for subsequent VSM analysis and simulation.Lean improvement and simulation optimization of production process of foundry shop.Firstly,current VSM is drawn based on real-time data acquisition in physical workshop.Secondly,the source of production line redundancy was found out,the production process was optimized and reorganized,and the future VSM was further drawn.According to VSM,the workshop Flexsim simulation model was established to analyze the optimization results.Finally,the improvement scheme and virtual workshop model that meet the requirements are obtained.By this method,the balance rate of the production line is increased from 51%to 72%.Product value-added time reduced from 273 seconds to 236 seconds;The value-added rate increased from 0.06 percent to 0.13 percent;The overall utilization rate of equipment is improved.The results show that the lean improvement model is an effective and reliable method to solve the hidden redundancy problem in the production process.