Design And Implementation Of Coupler Knuckle Maintenance Workshop Management And Control System Based On Digital Twin

In the development process of intelligent rail transit,effective data perception,transmission,representation,and utilization bring broad application prospects for data fusion driven intelligent operation and maintenance of rail transit.Vehicle maintenance is one of the important links for the safe operation of rail vehicles.At present,the maintenance of rail vehicles in China generally has problems such as low automation,insufficient real-time management and control capability of workshops,and data is not closed-loop,as one of the key components of vehicle connection,the health of the coupler knuckle during service is directly related to the operation safety of the train.To solve the above problems,this article takes the coupler knuckle maintenance workshop of railway wagon as the research object.Firstly,a detailed analysis of the inspection and repair process of the coupler knuckle and the functional requirements of the control system of the maintenance workshop is conducted,and a six dimensional digital twin model of the maintenance workshop is proposed;Then,the intelligent maintenance line of the coupler knuckle is designed,and the digital twin key technologies such as scene and data visualization,data acquisition and exchange,and simulation work are studied;Finally,a management and control system for the coupler knuckle maintenance workshop based on digital twin was developed,which realizes the intelligent control of the coupler knuckle maintenance workshop to a certain extent,and provides some new thoughts for the upgrading and construction of the digital maintenance workshop of rail vehicles.The main research content of this article is summarized as follows:(1)Construction of a six dimensional model for the digital twin maintenance workshop.The maintenance process of the coupler knuckle and the functional requirements of the control system in the coupler knuckle maintenance workshop are analyzed,providing support for the design of the coupler knuckle maintenance line;Taking the maintenance workshop as the research object,a six dimensional digital twin maintenance workshop model was constructed from six dimensions: physical maintenance shop,virtual maintenance shop,services,digital data,overhauled object,and connection.(2)Modeling of digital twin environment for the coupler knuckle maintenance workshop.An intelligent maintenance line for the coupler knuckle maintenance workshop was designed,which mainly includes the magnetic particle inspection station,the wear detection station,the welding and post-welding treatment station,the spray painting and drying station,and other stations,and the overall layout of the workshop is planned.On this basis,the modeling process of workshop visualization scenes is elaborated from six parts: 3D modeling,model lightweight processing,establishing coordination relationships,behavioral constraints,model validation,and model optimization;Based on the MQTT data communication architecture,data exchange between virtual and real workshops has been achieved,and a data exchange model for virtual and real workshops has been established,achieving anomaly detection of gateway nodes;Based on the Petri net modeling method,the logical modeling of the maintenance process of the coupler knuckle is carried out to achieve fusion mapping of on-site maintenance logic.(3)Digital twin modeling of the main equipment in the coupler knuckle maintenance workshop.Taking self-developed six axis robots and conveyor belts as research objects,the system architecture of the robot digital twin control subsystem is first proposed,which mainly includes the entity layer,model layer,data layer,and application service layer;Then,the digital twin modeling process of robots is elaborated in detail from the aspects of prototype design and production,control system design,digital robot establishment,data interaction and implementation,and health management;Finally,the modeling of the digital twin of the conveyor belt is achieved through 3D modeling,control system design,and simulation process modeling.(4)System construction and testing.Based on Unity 3D for system construction,the system functions are divided into three main functional modules: visual monitoring,maintenance operation simulation,and coupler knuckle maintenance tracking.Visual monitoring has achieved visual representation of the scene and data display in the coupler knuckle maintenance workshop,effectively enhancing the interactivity of workshop data;Maintenance operation simulation is based on a Petri net model of the coupler knuckle maintenance process,which defines the action rules of workshop equipment and drives the simulation operation of the coupler knuckle maintenance process through signals between equipment;Coupler knuckle maintenance tracking is the process of updating and real-time storing the relevant status parameters of the coupler knuckle in the current workshop,and developing a data export function to facilitate the later viewing of the coupler knuckle maintenance data.Finally,the virtual and real environment of the coupler knuckle handling station is constructed,the system is verified,and the system is summarized and analyzed.