Research on a Real-Time Control System for Discrete Factories Based on Digital Twin Technology

Gear factories are most typical discrete manufacturing factories. Many gear factories are striving to explore how to achieve intelligent manufacturing in order to improve efficiency and reduce costs. Digital twin technology is currently one of the most reliable ways to achieve intelligent manufacturing. This article aims to establish a real-time control system in order to promote intelligent manufacturing for discrete manufacturing factories. Firstly, a model for a digital twin gear factory is put forward based on the characteristics of gear factories, and the composition of a real-time control system for gear factories is clarified. Then, a human-computer interaction architecture for the real-time control system is proposed. The real-time control system consists of three parts as follows: a monitoring module, a virtualizing module, and a controlling module. At work, it appears as a kind of human-machine interaction form with the three following interfaces: a monitoring window, a virtualizing window, and a controlling window. Finally, a gear factory, which is specialized in manufacturing the intermediate shaft dual gear of a new energy vehicle gearbox, develops a set of software for the real-time control system. The prototype software is obtained through some development activities such as 3D MAX and WebGL virtualization modeling and OPC UA and REST communication design.