Controller integrated digital twin for online optimization of forming processes

当前产品的个性化导致小批量生产，导致大量的变体，并要求进一步提高钣金成形业务的生产率。动态效应、材料性能波动、控制偏差以及机床和工具性能与磨损相关的变化都会影响精度，这使得基于经验的生产参数预测几乎不可能实现。仿真模型被广泛用于今天的机器，过程及其相互作用的分析，以及机器控制的虚拟调试。这些模型能较高精度地预测机床状态和成形结果。然而，缺乏可管理的方法来创建和计算整体系统仿真模型，使过程和所有涉及的生产设备可分析。如果可以用一个整体的实时系统仿真模型来计算机器、过程及其相互作用的虚拟映像，并将该模型作为同步运行的数字孪生实现在机器控制上，则可以在几笔内预测过程参数并实现过程控制。这将有助于缩短刀具上料时间，减少废料，并显著提高钣金成形过程的效率。该项目的目标是为成形技术创建一个实时控制集成系统仿真环境，实现基于生产线数字孪生预测的在线过程控制。将开发一个模型库，并在演示机的控制系统中实施。该库将为钣金件生产提供两个示例过程的实时模拟-深拉深和剪切切割-再加上系统仿真中的机器模拟。控制集成数值计算的仿真环境将为冲程间过程控制提供技术依据。该项目的成功与更换工具后生产启动时间的显著缩短有关。系统对材料和环境条件波动的实时反应可以避免生产误差，实现零误差生产。

The current individualization of products causes smaller batch sizes and leads to larger numbers of variants and demands further improvement of productivity in the sheet metal forming business. Dynamic effects, fluctuations in material properties, control deviations and wear-related changes in the properties of the machine and tool, that influence accuracy, make experience-based prediction of production parameters virtually impossible. Simulation models are widely used for today’s analysis of machines, processes, and their interactions as well as for the virtual commissioning of machine controls. These models can predict machine states and the forming result with high accuracy. However, there is a lack of manageable methods for the creation and calculation of holistic system simulation models that make the process and all the production equipment involved analyzable. If the virtual images of machines, processes and their interactions can be computed with a holistic real-time system-simulation model and can the model be implemented on the machine control as a synchronous running digital twin, then predictions of the process parameters can be made within a few strokes and a process control can be implemented. This will help to shorten tool ramp-up times, to reduce scrap and to increase the efficiency of sheet metal forming processes significantly. The objective of the project is to create a real-time control-integrated system simulation environment for forming technologies that enables online process control based on the predictions of the production line’s digital twin. A model library will be developed and implemented in the control system of a demonstrator machine. The library will provide real-time simulations of two exemplary processes for sheet metal part production - deep drawing and shear cutting - coupled with a machine simulation in a system simulation. The simulation environment for control-integrated numerical calculations will provide the technical basis for stroke-to-stroke process control.The success of the project is linked to significantly shortening the production start-up time after tool change. The real-time reaction of the system to fluctuations in material and environmental conditions leads to the avoidance of production errors with the aim of zero error production.