A digital twin-based machining motion simulation and visualization monitoring system for milling robot

• Published in: International journal of advanced manufacturing technology Vol. 127; no. 9-10; pp. 4387 - 4399
• Main Authors: Zhu, Zhaoju, Lin, Zhimao, Huang, Jianwei, Zheng, Li, He, Bingwei
• Format: Journal Article
• Language: English
• Published: London Springer London 01.08.2023; Springer Nature B.V
• Subjects: Algorithms; CAE) and Design; Computer-Aided Engineering (CAD; Digital twins; Engineering; Finite element method; Industrial and Production Engineering; Mapping; Mechanical Engineering; Media Management; Milling (machining); Monitoring; Monitoring systems; Motion simulation; Original Article; Real time; Robot dynamics; Robots; Simulation; Simulation models; Trajectory planning; Visualization; Digital twin; Visualization monitor; Machining motion simulation; Milling robot
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-11827-x

Compared with traditional CNC machines, robot milling has the advantages of low cost, high flexibility, and strong adaptability, providing a new solution for complex surface machining. However, robot machining trajectory planning in the real world is time-consuming and has safety risks. At the same time, how to achieve 3D visualization monitoring in the milling process effectively is also a challenging problem. Digital twin technology, with its characteristics of multi-dimension, high-fidelity, virtual-real fusion, and real-time interaction, provides an effective way to solve these problems. For this purpose, the paper designs and implements a robot milling motion simulation and visualization monitoring system based on the digital twin system framework. The system uses the Unity3D platform to construct the robot’s digital twin body, designs a material removal algorithm based on mesh deformation, and establishes a milling motion simulation model. Through virtual-real mapping technology, the system establishes a bidirectional communication between virtual and physical entities and achieves the result mapping of the robot milling motion simulation and the visualization monitoring of the milling process. Finally, the motion simulation and real-time visualization monitoring of the milling process are tested, verifying the effectiveness and timeliness of the system.