基于UE5的真空悬浮熔铸设备数字孪生模型构建

Construction of a digital twin model for vacuum suspension melting equipment based on UE5

  • 摘要: 针对真空悬浮熔铸设备在极端工况下,面临多源异构数据缺乏时空关联集成呈现、数据碎片化及熔炼过程黑箱化难题,提出一种基于Unreal Engine 5(UE5)的数字孪生模型构建方法。首先,采用“特征-运动”联合轻量化策略与功能-结构解耦方法,构建了精准映射设备动作序列的工艺行为模型;其次,基于集总参数法推导熔铸过程的物理降阶模型,建立了物理状态参数集与Niagara粒子系统的动态映射机制,实现了对熔体微观演变的可视化重构。验证结果表明,该模型能够精准执行全工艺流程,实现从宏观机械运动到微观金属相变的高保真动态表征;与传统建模方法相比,模型面片数量降低了34.3%,系统运行帧率提升了35.1%。该方法有效调和了工业级数字孪生模型在高保真机理表征与交互实时性之间的矛盾,为复杂装备的智能运维高阶孪生应用提供了可视化模型基础。

     

    Abstract: The challenges regarding the lack of integrated spatio-temporal representation of multi-source heterogeneous data, data fragmentation, and the "black box" phenomenon of the melting process in vacuum suspension melting equipment under extreme working conditions are addressed in this paper. Consequently, a digital twin model construction method based on Unreal Engine 5 (UE5) is proposed. Firstly, a process behavior model that accurately maps equipment action sequences is constructed by employing a "feature-motion" joint lightweight strategy and a function-structure decoupling method. Secondly, a physical reduced-order model of the melting process is derived based on the lumped parameter method, and a dynamic mapping mechanism linking physical state parameters with the Niagara particle system is established, through which the visual reconstruction of the melt's microscopic evolution is realized. Validation results indicate that the full process flow is accurately executed by the model, achieving high-fidelity dynamic characterization spanning from macroscopic mechanical motion to microscopic metal phase transitions. Compared with traditional modeling methods, the polygon count of the model is reduced by 34.3%, and the system operating frame rate is increased by 35.1%. The contradiction between high-fidelity mechanism characterization and real-time interactive performance in industrial digital twins is effectively reconciled by this method, providing a visual model foundation for high-level digital twin applications such as intelligent operation and maintenance of complex equipment.

     

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