Realizing the “Digital Twin System” for Industry 4.0 with Embedded Sensing and BLE

mars4zhu

Realizing the “Digital Twin System” for Industry 4.0 with Embedded Sensing and BLE [Copy link]

Realizing the “Digital Twin System” for Industry 4.0 with Embedded Sensing and BLE

Author: mars4zhu

1. Introduction

With the vigorous development of embedded sensors, low-power wireless communication technology and efficient signal processing technology, the Internet of Things technology has experienced explosive development and growth. When exploring the relationship between digital twins and the Internet of Things, it can be found that data connection is regarded as one of the core elements of digital twins in different definitions of digital twins. The reason is that the digital twin virtual model needs to update the digital information of the physical entity in real time, and the processed information must also be transmitted from the virtual model to the physical entity to achieve two-way real-time mapping between the physical entity and the virtual model. In the basic application of digital twin technology, the basic goal is to achieve full synchronization between virtual models and physical entities. On this basis, digital twins can achieve higher-level goals such as data analysis and product/equipment optimization.

Project Description:

This project is aimed at the "digital twin" in the industrial control field where our company is located, that is, the synchronization of physical entities and virtual models.

(1) Use software to simulate a digital simulation system of an actual device on a mobile phone/PC, and use mathematical equations in the field to accurately simulate the dynamic change process of physical quantities in reality (such as fluid, heat and other multi-field processes in our company's power electronic cooling equipment). Then, use low-power wireless communication technology to transmit the simulated physical quantities to an external control device.

(2) Since it adopts fully digital physical mathematical modeling, its simulation fits the actual changes very well, and it can easily test whether the control strategy of the control device is correct in the actual dynamic change process. It can also simulate faults that cannot be directly operated on the actual equipment (such as large-scale pipeline leakage, temperature exceeding the limit and other extreme faults), thereby verifying the complete and correct control function of the control device;

(3) This process can also be synchronized in both directions. The actual state quantities of external equipment (such as the temperature, pressure, and flow rate of the heat dissipation equipment) are collected by sensors and connected to the digital twin system on the mobile phone/PC, realizing multi-point WSN (wireless sensor network) and condition monitoring of industrial equipment. The Internet of Things enables the digital twin system to reflect the status of the actual equipment in real time and accurately. The digital twin system can be simulated and controlled before actual operation to improve the ability of data analysis and product/equipment optimization.

2. System Block Diagram
After getting familiar with the software and hardware of RSL10, the core board of the digital twin control board was designed using Altium Designer. The same interface as the original digital twin standard core board was used, and direct replacement was sought. The schematic diagram is as follows:

The designed RSL10 core board PCB diagram is as follows, and compared with the standard core board,

Comparison of PCB design of RSL10 core board (left) and standard core board (right)

3. Functional description of each part

Matlab is used as a modeling tool for digital twins. For multiple physical domains such as fluid and heat transfer involved in this project, a hybrid modeling approach is adopted and simulation is performed to obtain the simulation values of various physical quantities in the process.

After continuous optimization and improvement, the accuracy and behavior of the model can be closer to the real system. What is needed now is to feed back the simulation value to the control system on the digital twin baseboard in real time through the digital twin core board, so as to realize the closed-loop control design of the digital twin.

4. Source Code

Schematic diagram and PCB design of SDB_Core_RSL10 ;

SDB_Core_RSL10.zip (1.53 MB, downloads: 3)

5. Demonstration video of the work’s functions

(None)

6. Project Summary

Since RSL10 adopts QFN48 package and flexible DIO pin configuration, each DIO pin can be freely assigned almost all internal signals of the chip, which greatly facilitates hardware design. The flexible power supply configuration also makes the power consumption performance of RSL10 stand out among a number of BLE chips.

采用嵌入式传感和BLE实现工业4.0的“数字孪生系统【作者：mars4Zhu】.docx (772.95 KB, downloads: 3)