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

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Abstract

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.

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The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Funding

This work was supported by the National Natural Science Foundation of China (No. 52205455), and the Natural and Science Foundation of Fujian Province (No. 2021J01560).

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Fuzhou University, Fuzhou, People’s Republic of China

    Zhaoju Zhu, Zhimao Lin, Jianwei Huang, Li Zheng & Bingwei He

Authors
  1. Zhaoju Zhu
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  2. Zhimao Lin
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  3. Jianwei Huang
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  4. Li Zheng
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  5. Bingwei He
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Contributions

Zhaoju Zhu worked on conceptualization, methodology, formal analysis, and preparation of the original draft with input from all authors. Zhimao Lin developed the digital twin system, designed the simulation model and algorithm, and conducted the experiments. Jianwei Huang and Li Zheng worked on data collection and processing. Bingwei He was responsible for work inspection.

Corresponding author

Correspondence to Zhaoju Zhu.

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Zhu, Z., Lin, Z., Huang, J. et al. A digital twin-based machining motion simulation and visualization monitoring system for milling robot. Int J Adv Manuf Technol 127, 4387–4399 (2023). https://doi.org/10.1007/s00170-023-11827-x

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  • DOI: https://doi.org/10.1007/s00170-023-11827-x

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