Controller integrated digital twin for online optimization of forming processes

当前产品的个性化导致了更小的批量，并导致了更多的变种，并要求进一步提高板材成形企业的生产率。影响精度的动态效应、材料性能的波动、控制偏差和机床性能的磨损变化，使得基于经验的生产参数预测几乎是不可能的。仿真模型被广泛用于当今对机器、过程及其相互作用的分析以及机器控制的虚拟调试。这些模型可以较高精度地预测机器状态和成形结果。然而，缺乏可管理的方法来创建和计算整体系统仿真模型，使工艺和所有涉及的生产设备都可以分析。如果可以用整体实时系统仿真模型计算机器、过程及其相互作用的虚拟图像，并且该模型可以作为同步运行的数字孪生兄弟在机器控制上实现，则可以在几个行程内预测过程参数，从而实现过程控制。这将有助于缩短模具安装时间，减少废品，并显著提高板材成形过程的效率。该项目的目标是为成形技术创建一个实时控制集成的系统模拟环境，以实现基于生产线数字孪生件预测的在线过程控制。开发了一个模型库，并在某演示机控制系统中进行了实现。该库将提供板材零件生产的两个示例性过程的实时模拟--拉深和剪切--以及系统模拟中的机器模拟。该控制一体化数值计算仿真环境将为冲程过程控制提供技术基础，该项目的成功与否直接关系到换刀后生产投产时间的大幅缩短。系统对材料和环境条件的波动做出实时反应，从而避免生产误差，目标是零误差生产。

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.