Simulation and Monitoring of Marine Diesel engine

Machining workshop based on digital twin

Xifeng Fang (  xffang2006@163.com )
Jiangsu University of Science and Technology
Mingyi Guo
Zhongtai Hu
Qi Wu
Shengwen Zhang
Chanyuan Gong
Tongyue Wang
Qun Li

Research Article

Keywords: Marine diesel engine, Digital twin workshop, Twinning simulation, The twin monitoring

Posted Date: August 9th, 2022

DOI: https://doi.org/10.21203/rs.3.rs-1900972/v1

License:   This work is licensed under a Creative Commons Attribution 4.0 International License.
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 Simulation and Monitoring of Marine Diesel engine
Machining workshop based on digital twin
Xifeng Fanga, Mingyi Guoa,1, Zhongtai Hua ,Qi Wua , Shengwen Zhanga ,Chanyuan
Gonga, Tongyue Wangb Qun Lic
a. Institute of advanced manufacturing technology, Jiangsu University of Science and
Technology, Zhenjiang, 212003, China
b. Jiangsu Key Laboratory of Advanced Manufacturing Technology，223003, China
c. Hudong Heavy Machinery Co..LTD, Shanghai, 200129, China
Abstract: In order to solve the current large processing workshop information degree is low, part of the
information can not be immediately grasped, reaction lag and other problems. In this paper, key
techniques of twin Marine diesel engine to develop digital processing workshops, the traditional Marine
diesel engine processing workshop combined with digital twin technology, through the twin body build
four-dimensional model the virtual workshop is established in this paper, based on the digital twin
software service platform building workshop, unicom virtual workshop and physical workshop, make
full use of the whole life cycle of Marine diesel engine processing data, Realize twin simulation and
monitoring of physical workshop. Finally, the practical case is used to verify the practicality of the system.

Key words Marine diesel engine; Digital twin workshop; Twinning simulation; The twin monitoring

1 introduction
Marine diesel engine, as the core power plant of large ships, has high manufacturing technology and
strong systematization in the ship industry. The Marine diesel engine manufacturing level is still larger,
mainly as follows: (1) the process equipment is relatively backward, the machining process equipment
still is given priority to with ordinary machine tool, a Marine diesel engine machining workshop nc
machining equipment of enterprise accounts for only around 30%, while manufacturing key components
in the developed countries workshop numerical control rate can reach more than 80%;(2) the advanced
computer technology is not perfect, especially used in Marine diesel engine processing of digital
technology, such as CAX, PLM, etc., these technologies are not popular, even if the introduction of
application but not fully, the western developed countries have such technologies are widely used and
developed related system, improves the flexibility, integration of manufacturing floor, And then greatly
enhance the international market competitiveness;(3) Low degree of automation and digitalization in the
processing workshop, insufficient data collection and utilization in the workshop, so that the whole
processing process is not transparent, managers can not accurately control the workshop, resulting in
long production cycle of products, quality can not be guaranteed. Twin Marine diesel engine for digital
processing workshops, therefore, to study the key technology, build a twin monitoring, simulation and
evaluation prediction system of digital twin processing workshops, feedback control, realize the process
information dynamic state analysis, real-time perception, workshop control transparency, promote
formation of the corresponding application architecture, technical route and the software system,

1Corresponding author.
E-mail address: 1727752333@qq.com (Mingyi Guo).
Production of Marine diesel engine in the process of information island and all connected to the
maintenance to the predictive maintenance, experience after coordination to intelligent decision-making,
has important theoretical significance and practical value, hope to be able to to improve the level of
Marine diesel engine manufacturing, formation of Marine diesel engine intelligent manufacture mode,
promoting the manufacture level of industry competitiveness.
The concept of "information mirror model" was first proposed by Professor Michael Grieves[1]. So
far, it has gradually evolved into a high-fidelity simulation model that can reflect the whole life process
of physical entities, which is called digital twin model[2]. The three elements of digital twin technology
include physical entity, virtual model and information interaction between them. As shown in Figure 1,
many advanced science and technology such as big data, virtual reality and artificial intelligence have
been studied and applied in various fields. Digital twin technology difference between the real objects in
space can be mapped to a virtual space formed in the virtual model, and implement two-way control of
physical objects and the virtual model, and system engineering, multidisciplinary modeling and
simulation, data mining technology can be used as a digital support technology of the twin, assigned to
the virtual model of evolution for the digital twin body, Enhancing the information interaction between
physical objects and digital twins makes the technology more intelligent[3].

Fig. 1 Technology tree[4]

At present, the application of digital twin technology in medical, industrial and urban fields has
been widely studied. With the proposed strategies of "Made in China 2025" and "Industry 4.0" at home
and abroad, digital twin technology has occupied an important position in the process of upgrading from
traditional manufacturing to intelligent manufacturing[5]. Yildiz[6] proposed the concept and
architecture of digital twin virtual factory to verify the effectiveness of digital twin factory in the full
cycle of wind turbine manufacturing. Thomas with Graessler[7,8] were established based on the number
of twin study factories and twin production systems, based on the number of employees learn factory can
provide small and medium-sized enterprises with easy to use, scalable, service oriented control system
for learning, based on the number of employees and twin humanized production system to employees as
one of the control condition The whole system has higher openness and comfort. Pedro et al.[9] used
MTConnect to associate machine tool data with manufacturing execution system data, and on this basis,
built digital twin workshop to control and optimize production. The team led by Professor Tao Fei [10,11]
from Beihang University put forward the concept of Digital Twin Workshop based on Digital Twin, and
elaborated the system composition (physical Workshop, virtual Workshop, Workshop Twin data,
Workshop service system), operation mechanism, key technologies, etc. Further, the theory and method
of information physical fusion in digital twin workshop are deeply discussed from four dimensions of
physical fusion, model fusion, data fusion and service fusion, which provides a reference for the practice
and application of digital twin workshop. Jiang Haifan et al.[12] studied the evolution mechanism and
operation mechanism of digital twin workshop, explored the construction method of digital twin
workshop model based on the information flow, material flow and control flow in the workshop
production process, and described the evolution law from physical workshop to digital twin workshop.
Finally, the technology roadmap of digital twin workshop, operation mechanism and enabling technology
of each stage are given.
In terms of digital twin modeling, P. Aivaliotis et al.[13] used the modeling method based on
advanced physics to model the digital twin of industrial robots, and verified the feasibility of the digital
twin used in the field of predictive maintenance. Bruno Scaglioni et al.[14] used the object-oriented
method to conduct kinematics and finite element modeling of Mandelli M5 machine tool with Modelica
language and FEM method respectively, and realized the digital twin dynamic model construction of the
machine tool. Singh Soumya et al.[15] proposed the concept of "toolbox" for digital twin modeling. The
algorithms, frameworks, software platforms and other tools needed to build digital twin models are all
contained in the "toolbox", and users can use any element in the toolbox to assist in digital twin modeling.
Luo et al.[16] used the unified modeling method of multi-domain to model digital twin for NC machine
tools, and proposed the mapping strategy from physical space to virtual controls, realizing the fault
diagnosis and prediction of NC machine tools. In order to faithfully reflect the state changes in the
processing process of aerospace components, Liu et al. [17]proposed a bionic digital twin modeling
method, and finally realized the construction of high-fidelity multi-scale digital twin in the physical
processing process. Yu et al.[18] proposed a hybrid modeling method based on operation data and first
principle mechanism for turbine performance monitoring at different power levels, and achieved good
monitoring results. Jiang et al.[19] applied the discrete system modeling theory to construct the digital
twin model of the production line in order to efficiently construct the virtual model of the complex
production system and connect it with the physical entity. In order to build the digital twin model of
cutting tools, Xie et al.[20] integrated the physical information of cutting tools and processing data, and
on this basis, completed the two-way real-time interaction and fusion of physical information and virtual
data, and finally realized the construction of digital twin model in the whole life cycle of cutting tools.
In terms of predictive maintenance, Xin Yang et al.[21] proposed a digital twin-driven performance
prediction framework, which combines data-driven and model-driven prediction methods. Experimental
results show that the framework is more accurate and effective than the single performance prediction
method. Weichao Luo et al.[22] proposed a predictive maintenance method combining digital twin model
driven and digital twin data driven, and verified the reliability of the method in the experiment of
predicting tool life. Yan Xu et al.[23] realized digital twin auxiliary fault diagnosis in two stages of
development and maintenance by using deep learning technology. Traditional predictive maintenance
models rely too much on historical data. To solve this problem, Wihan Booyse et al.[24] proposed a deep
digital twin model, which pays more attention to the use of real-time data. Shanghua Mi et al.[25]
discussed various factors that affect maintenance decisions, and proposed a predictive maintenance
framework of cross-organizational collaborative interconnection combined with digital twin technology
to make predictive maintenance decisions more accurate.
In the digital simulation and monitoring for twin meng jiaqi et al.[26] the problem of insufficient
response to a disturbance, in view of the present simulation system is put forward based on the edge of
cloud - fog - three layers of collaborative simulation system disturbance response method, through the
edge of the end of data preprocessing, customized training model in the clouds, in the fog the deployment
model, implementation of disturbance of rapid response system. In order to realize business data
monitoring of engine assembly workshop, Duan Ming H. et al.[27] built a digital twin assembly
workshop system including physical layer, data layer, virtual layer and service layer, and completed data
monitoring of engine assembly workshop on this basis. Du Yingying et al.[28] realized the three-
dimensional visual monitoring of industrial robot operations by establishing the robot digital twin and
constructing the virtual-real interaction channel. To solve the problem of the visualization degree of ship
assembly and welding production line, Tian Guizhong et al.[29] proposed to use PlantSimulation as the
platform to carry a virtual model of production line, and realize digital twin-driven production line
visualization by real-time monitoring data driven model. Mingyi Guo et al.[30] studied the simulation
and monitoring of machine tools, which can effectively reflect the collision of machine tools before
machining and during machining, as well as constantly predict the amount of tool wear.

2 Overall design of digital twin Marine diesel engine processing

workshop
Physical workshop is the basis of the application framework of digital twin Marine diesel engine
processing workshop, which includes all workshop elements and carries out production activities here,
thus generating a large amount of raw data, as shown in Figure 2.A complete physical workshop can be
in accordance with the actual production demand is divided into a number of production and processing
unit, the workpiece through the gantry crane, forklift and other transport equipment from the current
production and processing unit to the next unit, each unit is mainly composed of Marine diesel engine
key-module, execution and sensing detection equipment, Marine diesel engine key-module including
Marine diesel engine frame, connecting rod, crankshaft, etc.;Execution equipment mainly includes
processing equipment and transportation equipment, such as machine tools, gantry cranes and
forklifts;Sensor detection equipment includes all kinds of data sensors and quality detection equipment.
Digital twin service platform is the core functional platform of digital twin processing workshop,
as shown in Figure 2.2, including digital twin database (DT-WSD), data preprocessing module and core
function module.The twin database is used to store primary data and secondary data. The primary data
is collected from the physical workshop of Marine diesel engine processing, and some data may be
processed by edge computing.The secondary data comes from the core function module and data
preprocessing module of the service platform.The data preprocessing module is mainly responsible for
data format transformation, feature value extraction and other processing, so that the data can meet the
needs of all kinds of intelligent algorithms in the core function module.Core function module is a
collection of all kinds of core function code, include twin forecast simulation, evaluation, analysis and
decision, feedback control of four main modules, twin twin body elements of digital simulation module
using workshop simulation actual machining process, can be divided into single device simulation,
processing unit simulation, simulation and production line workshop simulation of different levels;The
evaluation and prediction module is mainly responsible for evaluating and predicting the machining
performance, processing energy consumption and other indicators of key elements in the physical
workshop in the process of twin simulation, or carrying out the next prediction based on the historical
data and combining the current data in the actual production process.The analysis and decision module
can analyze the parameters such as processing technology and testing technology in the process of
twinning simulation, and assist the process personnel to decide the optimal scheme. It can also analyze
the emergency situation in the actual process, and assist to decide the optimal solution.The feedback
control module is responsible for feeding back the decision data to the physical workshop in the actual
production process, and realizes the control of physical equipment with relevant hardware.
Virtual workshop is the display window of digital twin workshop. It can not only make use of 3D
scene to let users dynamically understand the upcoming or ongoing activities in physical workshop, but
also make users more intuitively understand the data information they are concerned about by combining
with charts.Virtual workshop shows the physical workshop scene in all aspects through 3D model, and
the 3D model of key elements such as machine tools and gantry cranes in virtual workshop combined
with the core function code in the service platform to form the digital twin of key elements, and each
digital twin together forms the digital twin of workshop.

3D scene of the virtual workshop

Models construction based on The lightweight of 3D models Scene modeling based on Constructing virtual workshop
3D modeling software based on 3ds Max CampusBuilder based on internet platform
3D models Machining Machining tool
3D models Workshop 3D models
parameters 3D models lightweight process kinematic model
construction layout design assembly
formulation design construction

Driving Feedback Driving Feedback

Virtual
workshop DT-MWSSP

Real-time visualization display of Monitor production efficiency Tool status and quality
Data driven processing
machining parameters and energy consumption control

Machining prediction analysis、optimization and decision-

Traditional systems
making subsystem

CAPP CAM
Data interface Machining prediction Machining optimization
model based on DT model based on DT
CAE CAD Data interaction

Machining decision-making
Logistics
... model based on DT
management

Data processing
module

Database of DT-WSD
Bridge
module
Interaction methods between physical workshop and bridge moudle
I/O Industrial Wireless
RFID PLC TCP/IP OPC UA
RS232/485 Ethernet network

Collecting Guiding

Raw Machining semi-finished Machining Machining

Physcial Product
material equipment product equipment equipment
workshop

Terminal Sensors Workers Terminal Sensors Workers Terminal Sensors Workers

Station 1 Station M Station N

Fig.2 Digital Twin Marine Diesel Engine Shop Application Framework

3. Digital twin modeling technology of key elements in

machining workshop
 Digital twin technology is characterized by digital reconstruction of physical entities in virtual space,
and the reconstructed objects have the same geometric appearance, behavior, physical properties and
other characteristics as physical entities. These objects in virtual space can be called digital twin.Digital
twin contains geometric model, physical model, behavior model and regular model. Geometric model is
used to describe the appearance geometry of physical objects.Physical model is used to reflect the
physical properties of physical objects and can be used for simulation analysis.Behavioral models are
used to describe the reactions of virtual entities influenced by different factors.Rule model is used for the
summary of invisible rules. Rules can learn and evolve by themselves, which enables virtual entities to
have the ability of evaluation, optimization and prediction[31].
3.1 Key elements digital twin geometric model construction
According to the method of building digital twin body geometry model, draw the milling machine
3 d model before, first carries on the modeling analysis, as a result of the milling machines in the
workshop position fixed, so the whole machine model can be divided into motion module and a fixed
module, movement module mainly for the various needs of shaft, the fixed module mainly consists of
beams, columns and other machine parts, Fixed modules can be properly drawn as a whole;Then, using
SolidWorks for modeling, the physical entity of NC gantry milling machine has many parts, and most of
the parts are not in the scope of the study, and in order to reduce the complexity of the model to reduce
the software running load, only focus on drawing the appearance of the shape and key parts, such as
spindle, bearing, etc.Next, the drawn parts model is assembled into a complete three-dimensional model
of the milling machine through constraint relations, as shown in Figure 3.
After the 3D model of the machine tool is constructed, it is converted into FBX file and added to
the Unity3D Project folder. Then, the Scene Scene is directly dragged into the corresponding folder of
the Project window to realize the import of the 3D model of the machine tool.
In the actual processing process, each axis of the machine tool is driven by the servo motor to
achieve displacement or rotation. If the linkage of the axis is to be realized, the CNC control system
needs to decompose the motion, and calculate the moving coordinates and moving speed of each axis,
and then transfer the moving instructions to the corresponding servo motor.There is no constraint
relationship between the parts of the machine tool model imported into Unity3D for the first time. In
order to achieve internal linkage between the parts of the machine tool model, the relative motion
relationship of the parts of the model should be constrained according to the parent-child definition
method. The final structure of the machine tool model is shown in Fig. 4.The parent object of each axis
in the model has the same position as the initial state of each axis, so the initial position coordinate of
each axis is (0,0,0), and each axis always moves relative to its parent object.
 Fig.3 Milling Machine SolidWorks Model
Gantry milling machine

X-axis parent object

The X axis

The sliding table

Y-axis parent object ……

The Y axis

Principal parent object

The spindle

Gantry milling column Spindle motor

Gantry milling beam The cutting tool

…… ……

Fig.4 Unity3D Gantry Milling machine model Parent-child relationship structure

3.2 Key elements digital twin behavior model construction
The digital twin of machine tool should contain functions such as G code interpreter, machining
trajectory simulation, collision detection, etc. This paper uses C# language supported by Unity3D engine
to write behavioral scripts to realize the core functions of the behavior model of the digital twin of
machine tool.

（1）G Code interpretation script

 As a NC programming language, G code (RS-274) is mainly used in NC machine tools. As an
important module in NC system, G code interpreter is mainly used to translate G code into instructions
that can be recognized by NC system.With G code and G code interpreter, NC machine tool can easily
realize functions such as fast positioning and circular interpolation in the processing process.In this paper,
some main functions of the G code interpreter are realized by writing C# based G code interpretation
scripts.The G code interpretation script defines the keywords commonly used in G code, such as "N, G,
X, Y, Z, I, J, K, F", and the number extraction function automatically parses the values after the keywords
and saves or outputs them according to the usage scenario.

（2）Machining trajectory simulation

In the actual machining process, the linear trajectory coordinates and arc trajectory coordinates in
the direction of non-single axis are obtained by the CNC controller through interpolation operation, and
then the output commands control the servo motor rotation of each axis, so as to realize the motion
control of each axis of the machine tool.In this paper, the motion control script is used to control the X
axis, Y axis and Z axis of the geometric model of machine tool, so as to realize the machining trajectory
simulation.In order to realize the simulation of machining trajectories in Unity3D engine as far as
possible, this paper uses the interpolation script to calculate the coordinates of line interpolation and arc
interpolation.First of all, explain the script reads the G code G code file, and then to the first line of the
file G code parsing, identify key words and extract the key value, if need to interpolation arithmetic will
be starting point coordinates and end coordinates and radius of the incoming data interpolation
calculation script, the script will calculate the single axis direction of line and arc trajectory coordinates
coordinates and store in an array, After the parsing of this line of G code is completed, the next line of G
code is parsed until the whole G code file is parsed, and a set of complete processing trajectory coordinate
array is generated.Finally, the motion control script reads each coordinate point in the machining
trajectory and decomposes it into X, Y and Z axis motion dispositions to generate displacement
instructions and control the linkage of each axis.

（3）Collision detection during machining simulation

Before the formal processing, one of the purposes of simulation verification of G code is to ensure
that no collision will occur in the processing process. In this paper, collision detection and alarm in the
simulation process of digital twin machining of machine tool are realized by using the built-in collider
component of Unity3D.Unity3D has several built-in collider components such as box collider, capsule
collider and grid collider. Table 1 lists the types and functions of some colliders.
Machine digital twin body in the process of machining trajectory simulation, if not collision,
suggests that G code program security, in order to accurately detect whether the collision occurred, to the
need for collision detection of objects to add Mesh Collider (Mesh Collider) components, and then write
collision behavioral script, stop at the instant of the collision simulation and output warnings, And the
object in collision becomes red.
Table 1 Unity3D Engine Built-in Collider Type Description
Collider name Collider shape The application case
Cuboid objects, doors, walls,
Box Collider The cube
etc
Spherical obstacles, falling
Sphere Collider spherical
rocks, etc
Capsule Collider Capsule type Characters etc.
Wheel Collider wheel A vehicle with wheels
 Mesh Collider Grid-based shape An object with a grid
Terrain Collider Shape based on terrain All terrain
3.3 Key elements digital twin physical model construction
In the process of milling machine, the tool, spindle and so on temperature, stress and other state
changes, the construction of digital twin physical model of milling machine can make users more
intuitive to understand the key parts in the process of processing state.
Taking milling cutter as an example, the shape of its model is relatively complex, and the surface
mesh generated by Unity3D is messy by default. Therefore, the finite element tetrahedral mesh is firstly
divided into the milling cutter model by MATLAB, and then the serial number of the meshes that have
been divided and the corresponding coordinate data of each vertex are exported as.txt files
respectively.The grid vertex number is used to determine the connection between each vertex, and the
coordinate data is used to determine the specific position of each vertex.Next, using the surface grid to
refactor c # script in Unity3D cutter model, the working principle of the script is to read two. TXT file
data, find out all grid vertex at the surface of internal vertex without drawing and display in the Unity3D,
then these are vertices on the surface of the model in accordance with the original serial number are
connected, At this time, the surface grid of milling cutter is the surface grid divided by MATLAB. For
the reconstructed milling cutter model, the serial number and position coordinates of each vertex have
been clearly known, which is convenient for the subsequent Shader program to perform color assignment
on each vertex.The default grid generated by Unity3D and the grid partitioned by MATLAB are shown
in Table 2.
Table 2Mesh generation comparison
Unity 3D generates a grid by
MATLAB tetrahedral mesh
default

Machining simulation process, the cutting tool by cutting force (F) some vertex point as the tool,
and each vertex force can be obtained by MATLAB simulation, extract tool surface force values of each
vertex, and its into the c # script function calculates the corresponding vertex color value should be given
different cutting force interval has a different color, For example, 0<≤(Fmax)/2 is blue, and (Fmax)/2<≤
is red. Finally, the color value is passed to the Shader program, and the GPU renders the cloud image
effect. 𝐹𝐹𝐹𝑚𝑎𝑥
3.4 Key elements digital twin rule model construction
 Bearing is a common, important and vulnerable part in machine tools, and its health status will
directly affect the machining performance of machine tools, so it is necessary to monitor its health status.
This paper will build a bearing life prediction model as a regular model to reveal the bearing performance.
3.4.1 Data description of rule model construction
This data set is provided by xi 'an jiaotong university, as shown in figure 5 to obtain the data sets of
rolling bearing test rig, by supporting bearings, ac motor, acceleration sensor and test the bearing parts
of the test platform can adjust different radial force and rotational speed to simulate different conditions,
the hydraulic loading system to produce radial force is used to test the bearing housings, The motor speed
controller adjusts the speed[32].

Fig.5 Rolling Bearing Accelerated Life Test Bench[33]

The experimental bearing is LDK UER204 type rolling bearing, and the relevant parameters are
shown in Table 3. There are three working conditions in this test, as shown in Table 4.
Table 3 LDK UER204 Type Rolling bearing Parameters
The parameter name The numerical
Inner ring raceway diameter /mm 29.30
Outer ring raceway diameter 39.80
/mm
Ball diameter /mm 7.92
Ball number 8
Bearing median diameter /mm 34.55
Contact Angle/(°) 0
Basic rated dynamic load /N 12820
Basic rated static load /kN 6.65
Table 4 Accelerated Life Test Conditions
Condition number Speed (r/min) Radial force/kN
1 2100 12
2 2250 11
3 2400 10
3.4.2 Model construction data preprocessing
The data set contains the whole life cycle data of the test bearings, and part of the bearing signal
data is shown in Figure 6. In order to effectively train the algorithm model, the data set needs to be
preprocessed.

(a) Bearing 1_1 horizontal direction signal (b) bearing 1_1 vertical direction signal

(c) Bearing 3_5 horizontal direction signal (d) bearing 3_5 vertical direction signal
Fig.6 highly tested bearing full life cycle signal
To determine the resampling time interval, firstly, based on the original 1.28s sampling interval, the
data set is further divided into 0.32s, 0.08s, 0.04s, 0.01s, 0.005s, 0.0025s and 0.00125s.Then, the
theoretical value 1 under the healthy state of the bearing is taken as the source domain, and the actual
data collected is taken as the target domain. The MMD (Maximum Mean Discrepancy), which measures
the similarity between the Source Domain and the Target Domain in transfer learning, is used to calculate
the similarity between the Source Domain and the Source Domain at different sampling intervals and
then draw curves to depict the bearing health. This is shown in Figure 7.As can be seen from FIG. 3.10,
with the shortening of sampling time, the trend of bearing health degradation curve becomes more
obvious, and the curve with sampling interval of 0.0025s and 0.00125s shows a very similar trend. In
order to avoid too much data resulting in too long model training time, 0.0025s is selected as the manual
resampling time interval. Indicates that each vibration data is further subdivided into 512.
𝑀𝑀𝐷[𝐹, 𝑝, 𝑞]
≔ 𝑠𝑢𝑝(𝐸𝑝 [𝑓(𝑥)] − 𝐸𝑞 [𝑓(𝑦)]) (3.8)
Where, -- the maximum average difference;𝑀𝑀𝐷F -- mapping function;P - x distribution;Q - y
distribution;Sup - upper bound;Ep-p distribution expectation;Eq -- q distribution expectation;F - kernel
function
Bearing vibration signal contains the mean, standard deviation, peak, kurtosis index, the time
domain characteristics, such as standard deviation, frequency of root mean square and the root mean
square of spectrum contains both frequency and other frequency domain feature index, for the selection
of suitable characteristic value, calculate the re-sampling after each vibration data of time domain and
frequency domain characteristic value, draw the characteristic value of the whole life cycle curve, The
characteristic values which can better reflect the degradation process of bearing from normal to failure
are selected as the input of the model.

(a) Degradation curve at 1.28s and 0.32s sampling time (b) Degradation curve at 0.08s and 0.04s
sampling time

(c) Degradation curve at 0.01s and 0.005s sampling time (d) Degradation curve at 0.0025s and
0.00125s sampling time
Fig.7 Bearing degradation curves at different sampling intervals
The data set of bearing 1_1 under the condition of 35Hz12kN is taken as an example. There are 123
vibration signal data stored in CSV files in the data set. After resamsampling, 62976 is regarded as the
total life cycle number of bearing life, indicating that bearing 1_1 is completely invalid and discarded
after running for 62976 cycles.The head of the training set and its meanings are shown in Table 5. Each
working condition has 5 experimental bearings, labeled 1~5.Cycle represents the current operating cycle
of the bearing, which is incremented from cycle 1 to the maximum operating cycle number of each
bearing.S1-s20 represents the eigenvalues of the input algorithm model, S1-S10 is the eigenvalues
extracted from the horizontal vibration signal, and S11-S20 is the eigenvalues extracted from the vertical
vibration signal. The types of eigenvalues extracted from the horizontal and vertical vibration signals are
the same.RUL represents the number of remaining cycles of the bearing, and the calculation formula is
Eq. (3.9). Label Indicates the prediction label. 0 indicates the normal status, and 1 indicates that a fault
is about to occur.Finally, the vibration signal data of five bearings under the working condition of
35Hz12kN are processed and assembled into a complete data set. Some data are shown in Table 6.
Table 5 Training Set header and meaning
Header name meaning
id Experimental bearing label
Number of current operating
cycle
cycles of bearings
s1-s12 The eigenvalue
Number of remaining cycles
RUL
of bearing
label Predict labels
Table 6 Part of the dataset
id cycle s1 ... s19 s20 RUL label
1 1 0.405592009 ... 0.354375097 0.524282902 62975 0
1 2 0.396883911 0.349723312 0.51548007 62974 0
... ... ... ... ... ... ... ...
3 80895 3.705639974 ... 3.592912195 5.441696362 1 1
3 80896 3.830212635 ... 3.707397297 5.618951605 0 1
... ... ... ... ... ... ... ...
5 26624 5.544094743 11.23186903 15.4316859 0 1

𝑅𝑈𝐿 = 𝑙𝑖𝑓𝑒 − 𝑐𝑦𝑐𝑙𝑒 (3.9)

Where, -- the number of remaining cycles;𝑅𝑈𝐿𝑙𝑖𝑓𝑒-- total bearing cycles;𝑐𝑦𝑐𝑙𝑒-- Current cycle number

of bearing.
3.4.3 Construction of bearing life prediction model based on LSTM
The conventional RNN network is prone to the problem of gradient disappearance or gradient
explosion during the training of Long time series data. Therefore, Hochreiter S et al.[34] improved the
conventional RNN network to form Long short-term memory (LSTM).
In this paper, LSTM method is adopted to divide the preprocessed data into training set and test set
according to 7:3, and input the network for training. The loss function image is shown in FIG. 8 (a), and
the life prediction curve is shown in Fig. 8 (b)

(a) Bearing life prediction loss function image

 (b) Bearing life prediction curve
Fig.8 Bearing life prediction loss and effect

4. Simulation and monitoring of machining shop based on digital

twin
4.1 Workshop simulation implementation based on Unity3D
The key element models in the virtual workshop will be imported into Unity3D with an XML
initialization document, as shown in Figure 9.The initialization file based on XML includes four modules:
geometric model, physical model, behavior model and rule model.The geometric model area stores basic
3D model information such as component name and geometry size.The physical model area stores the
material and Poisson's ratio information of the corresponding 3D model.The behavior model area is used
to store possible behavior keywords of the object, and the rule model is used to store relevant algorithm
keywords.By analyzing the geometric model area, the corresponding geometric model preforms can be
loaded and added to the virtual workshop scene.By parsing the physical model area, a data table is
automatically created for the loaded object in the database, which is used to store the data related to
it.Automatically associate related behavior scripts by parsing behavior model regions.Automatically
access the relevant algorithm API by parsing the rule model region.
 Initialization file based on XML

Geometric information

Geometric size

Parsing and loading

SI
Assembly relationship

… Files of geometric model

SI of physical information

Material
Parsing and creating
SI

Poisson's ratio

… Data tables

Behavior information

Behavior code of maching

Behavior module
Machining
Behavior code of collision
Parsing and calling
Collision
Behavior code of coordination

Key words of
code set Coordinat- …
ion
about behavior
…

Rule information

Function module
“Tool life prediction” Algorithm of tool life prediction

Parsing and calling Algorithm of machining

“Machining parameters
parameters optimization
optimization”

key words …
…
of algorithms

Fig.9 XML Initialization File Structure and Content

Behavior, the rules model area contains keywords can represent the simulation object name ALL
possible events, such as "processing", "crash", etc., and every event includes a time attribute, this
property by keyword, said that events triggered by the time conditions, the system can judge to the time
of each event, and if the keyword is "ALL", It indicates that the event satisfies the time condition from
the beginning to the end of the workshop simulation run, and ALL script components related to the event
in Unity3D will be activated, as shown in FIG. 10 (a), and wait for other triggering conditions. If the
keyword is not "ALL", relevant event scripts will be locked before the time condition of the event is
satisfied. As shown in Figure 10 (b), the script cannot be activated and the events in the script cannot be
triggered until the time condition is satisfied. After the script is activated, it waits for other triggering
conditions. All events will only be triggered when the time condition and other conditions are satisfied
simultaneously.

(a) Unity3D script activation status

 (b) Unity3D script lock status
Fig.10 Activation and Locking of Unity3D scripts
4.2 Workshop operation monitoring based on digital twin
Workshop job monitoring based on digital twin relies on reliable workshop data communication
means to ensure the reliability and integrity of twin data. It mainly includes two parts: graph visualization
of twin data and virtual device driver based on twin data.
4.2.1 Data communication Based on OPC UA
The most important concept in OPC UA communication architecture is the address space, and the
server is composed of address space and all functions are implemented based on address space. Fig. 11
shows the OPC UA server model[35].

OPC UA client
OPC UA address space

node
node node
node

node
node
node
node
node
node
``

node
node

node
node
node
node
node
node

Fig.11 OPC UA Server model

As the most basic unit of address space, node has many types, such as basic node class, object node
class, variable node class, method node class, etc.Table 7 shows the common attributes of nodes, where
M/O represents required and optional attributes, respectively.Reference determines the unique node
reference source, reference target node, reference semantics and reference direction[36].
Table 7 Address space node common Attribute Description
attribute The data type use instructions
Node ID, which uniquely identifies a node
NodeId NodeId M
in the server
Enumerations that define NodeClass, such
NodeClass NodeClass M
as variables or objects
Browse name, used for browsing purposes
BrowseName QualifiedName M only, should not be used to display the
name of the node
Displays the name, which contains the
DisplayName LocalizedText M
localized name of the node
Description, localized text that explains the
Description LocalizedText O
meaning of the node
Write masks expose the possibility of
WriteMask UInt32 O
clients writing node properties
 Consider the possibility of the exposed
UserWriteMask UInt32 O client writing node properties when the
user has access rights
According to OPC UA communication protocol, the data types collected by Marine diesel engine
processing workshop can be abstracted into the architecture shown in Figure 12.Environmental sensors
include temperature sensors, humidity sensors, noise sensors and other sensor subclasses, each subclass
contains different instances, instances have a variety of attributes, such as each temperature sensor has
manufacturers, models, temperature data and other attributes, each attribute can be collected and used as
data;Process equipment includes gantry milling machine, gantry crane, forklift and other subclasses, take
gantry milling machine as an example, it contains many parts, and shaft, lead screw, bearing and other
key parts are the key monitoring object, so such as spindle coordinate value attributes, spindle motor
voltage and current attributes should be monitored at all times;Marine diesel engine frame, connecting
rod and other in-process products belong to the subclass of processing products, surface roughness, shape
and position tolerance and other attributes should be collected and recorded;All the staff in the workshop
belong to the subclass of workshop staff. For each staff member, basic attributes such as body temperature
and height will be recorded.
Marine diesel engine processing
physics workshop

Workshop Shop process

environment Processed products Workshop staff
equipment
Temperature
sensor Marine diesel
Gantry milling engine frame Employees A
Temperature Surface
temperature
sensor 1 roughness
shaft
manufacturer …… height

The spindle ……
model ……
Temperature Spindle motor Employees B
value product
…… Voltage,current temperature
Temperature …… height
sensor 2 Coordinate ……
values
……
……
……
Noise sensor ……

Noise sensor screw

Vibration
The noise
signal
value
…… HasComponent
model
…… HasProperty
……
……
…… HasTypeDefinition
Environmental Process HasSubtype
sensor equipment

Fig.12 Data Architecture of Marine Diesel Engine Machining Shop

4.2.2 Digital twin model driven based on twin data
The real-time data collected by the physical workshop can be used to drive the virtual workshop
running, so that the status of the virtual workshop is consistent with that of the physical workshop, so as
to achieve the purpose of twin monitoring.Different from the workshop twinning simulation, the virtual
workshop running in the process of twinning monitoring does not need to consider the simulation strategy
and the linkage between the digital twins of different devices, and each digital twin is driven by the real-
time data collected by the physical workshop.
The process of twinning data to drive digital twinning can be roughly divided into two stages, as
shown in Figure 13.The first stage is twin data transmission based on OPC UA.The second stage is
Unity3D data parsing and model driven.
This paper developed the OPC UA client based on Python and integrated it into the back-end server,
opening up the data path between the back-end and the physical workshop. Real-time data is stored in
the database through this method, so that the subsequent data backtracking can be used to drive the
workshop to find out the existing problems at that time.
In order to verify the effectiveness of Unity3D's integration of OPC UA client, the OPC UA server
simulation software is used to simulate the machine side server for connection test. As shown in Figure
14 (a), UaExpert, the professional OPC UA client, is connected to the OPC UA server on the machine
side for data reading. Fig. 14 (b) shows that the OPC UA client developed based on Unity3D connects to
the machine tool server and reads data.
Files of geometric model Industrial
communication
methods Physical machine tool

OPC UA client
Bluetooth CNC controller
Interaction

OPC UA server
Parsing and
operating
Function module Behavior module RS-485

Mechanical
subsystem
Initialization file based on
XML

Data acquisition equipment

ZigBee
Feedback and control

Data collection and upload Electrical

subsystem
Parsing and operating
…
Data tables
Interaction
DT model of machine tool

Fig.13 Model-driven Digital twin based on OPC UA

(a) UaExpert data transfer test (b) Unity3D OPC UA client data transfer test
Fig.14 Data Transmission Verification Based on OPC UA
4.2.3 Workshop twin data visualization technology
The twin data visualization process can also be divided into two stages. The first stage is similar to
the first stage of digital twin drive, while the second stage is Unity3D data parsing and chart
rendering.Unity3D itself does not have mature chart functions. Although there is a chart plug-in package
in Unity's official store, it is expensive and has fewer styles. However, the effect of self-development
using UGUI is not as good as that of plug-ins, so it is necessary to seek a rich style, stable and reliable
chart display method.
 The flow of twin data visualization based on Pyecharts is shown in Figure 15.Because we want to
display the chart in the web page, we need to build a custom HTML file to render the chart, which can
be used as a template for subsequent charts. The HTML file defines the size of the chart, and we also
write a data receiving function to receive the dynamic data passed in from the back end.After the
rendering template is created, write Python scripts to determine the required chart type and chart style,
and create a data interface to read external dynamic data. Finally, turn on the chart rendering and
determine whether to save the chart as an image.Run the Python program, and if the graph is displayed
properly on the page, as shown in Figure 16, then the URL of the current page is extracted as
http://127.0.0.1:5000/.http://127.0.0.1:5000/Create Canvas at a suitable location in Unity3D
virtual workshop, place Browser(GUI) on this Canvas as its child object, and then fill the above URL
address in the corresponding location as shown in Fig. 17 (a). Running Unity3D can display the chart as
shown in Fig. 17 (b). Charts displayed using this method can be typeset or resized as needed during use.

Data icon HTML template build

Data icon Python script editing

Icon Type determination

Dynamic data reading

and adding

Icon Styling

Icon display and save

Unity3D data chart Canvas

created

Canvas chart page URL mount

Unity3D operation and chart

display

Fig.15 Twin Data visualization based on Pyecharts

Fig. 16 Pyecharts Web Chart

 (a) Web page URL

(b) Pyecharts chart display in Unity3D

Fig.17 Unity3D webpage URL filling and chart display
5. System verification
5.1 Construction of twin database in Marine diesel engine processing workshop
Aiming at the inconvenient storage of massive multi-source heterogeneous data generated in the
running process of the processing shop, by analyzing data characteristics, this paper conducts hybrid
modeling of dynamic data and static data of digital twin based on the deployed TDengine and SQL Server
data engine. The flow is shown in Figure 18.
 Bearing object analysis

Dynamic data
yes no
modeling

Data acquisition scheme Data acquisition scheme

analysis analysis
The data The data Sampling The data The data Sampling
…… ……
structure type frequency structure type frequency

Time series Database Relational database

construction construction

Table building Table building

Dynamic data writing Static data writing

Dynamic data modeling Static data modeling

Data interfaces are

created on connections

Fig.18 Dynamic and Static Data Hybrid Modeling process for digital twins
In Marine diesel engine processing workshop, the dynamic data generated or collected by machine
tools, sensors and other equipment mainly includes several characteristics: huge data scale, unified data
structure, stable addition mode and fixed time attribute. Now, the dynamic and static data modeling
process of bearings in the equipment is illustrated.
5.2 Function realization of digital twin workshop platform
In this paper, the algorithms developed for Marine diesel engine workshop are all based on Python
language. In order to integrate various algorithms and services more conveniently and simulate the actual
production environment, Python-based Flask is selected as the back-end server framework.In Ubuntu
system, Pycharm is used to develop and deploy the back-end server based on Python language and Flask
framework, so as to simulate the actual usage scenario.
5.2.1 Device management function
After entering the equipment management interface, users can have a detailed understanding of the
main equipment in the current workshop, as shown in Figure 19.The left side of the interface lists the
types of process equipment contained in the workshop, such as processing equipment, transportation
equipment, sensor equipment, etc. The right side displays the basic information of each device of the
previously selected type. Click to view the detailed information.In addition, users can add or remove a
device information at any time.
 Fig.19 Device Management function Interface
5.2.2 Virtual workshop scenario
Scene through the main interface of the "workshop" button to enter the Marine diesel engine virtual
scene processing workshops, figure 20 shows the workshop basic information, including the current time,
workshop environment, the current workshop as the number of running state, processing the product
name and workshop content, at the same time, the use of surveillance cameras can be real-time condition
monitoring of physical workshop, figure for the camera in the debug perspective.
Personnel
attendance
information
人员出勤信息表

Basic Workshop
车间基本信息
Information

Workshop
车间环境信息
Environment
Information

相机调试画面
Camera debugging
interface

Fig. 20 Workshop, basic information

Figure 21 shows the enlarged overall task progress information of the workshop, including the
workshop progress of the day, the week and the order task progress, so that the staff can understand the
current work progress and adjust the tasks in time to meet the schedule requirements.
 Workshop daily production Weekly workshop Workshop production
schedule
车间生产日进度 production
车间生产日进度 schedule order schedule
车间生产订单进度

Workshop daily production schedule

E n e r o g f y t c h o e n f s r u a m pe t i o n W o p r e k s a h t i o p n e q f u c i p m e c n y t
Fig. 21Workshop task progress
Figure 22 shows the basic information of workshop equipment after customized typesetting and
amplification, including equipment running status, equipment alarm information, etc.

车间设备能耗 车间设备运行/停机时间

T h e a l r m in f o r m a t io n
报警信息滚动表

Fig. 22 Workshop equipment information

Managers can enter the virtual workshop of Marine diesel engine by switching the perspective of
the keyboard. The virtual workshop contains digital twins of the key elements in the physical workshop
and has been laid out according to the physical workshop scenario.
To look at a key element in detail, such as a machine tool or a forklift, the user can double-click on
the model of the target element and the view will quickly move to the target element and display its
panel.Figure 23 shows the machine tool positioning perspective, including the function of machine tool
panel, the panel points module shows the current machine related content: basic information including
name of equipment, equipment number model, in charge of personnel, the current machining process and
the current equipment working condition (running, pause, stop, maintenance);Features include a process
simulation and equipment monitoring, including process simulation includes a combination of more than
a single device simulation and machine simulation, a single device simulation, which make use of a
single device G code processing simulation, joint simulation is used for processing unit or multiple
devices to a series of process simulation, only manual open joint simulation function of current
equipment to conduct joint simulation, Otherwise, only a single device can be simulated by default.
 Fig. 23 Machining Machine Perspective
The machine tool status monitoring and video monitoring can be opened in the equipment
monitoring functional area, and the obtained information can be displayed on the monitoring panel in
detail. Click the "" button in the upper right corner of the function panel to display the monitoring panel
of the equipment, as shown in Fig. 24.The monitoring content is divided into three parts: processing
information, sensor information and task information. The processing information mainly includes
spindle speed, tool model, axis coordinate value, etc. The processing information in the simulation stage
is mainly obtained by parsing G code and extracting keyword values from it, while the processing
information in the twinning monitoring process is mainly obtained from the physical equipment in real
time. The sensor information panel can display the data collected by the sensor from the physical
equipment in real time, such as bearing vibration signal; The task information shows the working content
of the current equipment in detail, including the current process, the current working step, and also shows
the working progress of the current task. The video monitoring function can obtain the real-time picture
of the machine tool through the camera in the physical workshop and display it in the system. Managers
can use this function to obtain the current real picture of the machine tool in real time.
 Fig.24 Machine Tool Monitoring Panel

6 Summary and prospect

This paper carried out the research on key technologies of digital twin Marine diesel engine
processing workshop, including digital twin modeling technology of key elements of processing
workshop, workshop simulation and monitoring technology based on digital twin. Based on these
technologies, combined with software platforms such as Unity3D and SolidWorks and scripting
languages such as Python and C#, a digital twin workshop software system is built. Based on the theory
of digital twin body four-dimensional model, is proposed based on Unity3D platform construction of
geometric model, behavior model, physical model and modeling method of the rules, and processing
workshops in milling planer, for example, by using the proposed method constructs the milling machine
digital twin body, further, on the basis of each key element number twin body, in accordance with the
physical layout of the workshop, A virtual workshop for Marine diesel engine processing was
built.Combined with physical workshop and virtual workshop, workshop simulation and monitoring
based on digital twin are studied and implemented. Workshop simulation includes single machine
simulation and joint simulation. Workshop monitoring includes virtual workshop driven by twin data and
visual display of twin data.The Flask framework built digital twin workshops backend server, the server
can provide data processing for the user service, intelligent algorithm, data communications services and
other kinds of services, including data processing services including data preprocessing, data format
conversion, etc., intelligent algorithm services include fault prediction, process parameter optimization,
etc., Finally, the processing results are fed back to Unity3D virtual workshop for display.
Due to the limitations of the platform in the integration of various functions and data interaction and
fusion, and limited by other factors, the author believes that the research work in this paper can still be
improved:
(1) the number of twin workshop software system data interface is reserved, but is still under
development, temporarily not connected to the enterprise existing CAPP and ERP system, lead to
insufficient data use, consider the system in the future research work to connect with other systems,
complete data interchange (edi) from the top to the bottom, really break the information island between
each system, To realize the closed-loop data of Marine diesel engine processing process;
(2) Although the interactive UI of digital twin workshop in this study has been arranged and
hierarchical by referring to relevant materials or templates, there are still some unreasonable points,
which will be adjusted in the process of adding and modifying functions in the future to make it more in
line with UI interaction logic.

Funding This research is strongly supported by Hudong Heavy Machinery Co., LTD , the Open Fund of
Jiangsu Provincial Key Laboratory of Advanced Manufacturing Technology (HGAMTL-1905) and
Zhenjiang Key Research and Development Program (GY2019003).
Conflicts of interest/Competing interests Not applicable.
Availability of data and material The datasets used or analyzed during the current study are available
from the corresponding author on reasonable request.
Code availability Not applicable.
Ethics approval Not applicable.
Consent to participate Not applicable.
Consent to publish Written informed consent for publication was obtained from all participants.
Author contributions Xifeng Fang: Supervision, Writing-Review & Editing. Mingyi Guo: Methodology,
Software, Writing-original draft. Zhongtai Hu: Software, Writing-Review. Qi Wu: for verification. Qun
Li: Operating the machine.

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