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Volume 11 Issue 3
Mar.  2024

IEEE/CAA Journal of Automatica Sinica

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Z. Jiang, C. Xu, J. Liu, W.  Luo, Z. Chen, and  W. Gui,  “A dual closed-loop digital twin construction method for optimizing the copper disc casting process,” IEEE/CAA J. Autom. Sinica, vol. 11, no. 3, pp. 581–594, Mar. 2024. doi: 10.1109/JAS.2023.123777
Citation: Z. Jiang, C. Xu, J. Liu, W.  Luo, Z. Chen, and  W. Gui,  “A dual closed-loop digital twin construction method for optimizing the copper disc casting process,” IEEE/CAA J. Autom. Sinica, vol. 11, no. 3, pp. 581–594, Mar. 2024. doi: 10.1109/JAS.2023.123777

A Dual Closed-Loop Digital Twin Construction Method for Optimizing the Copper Disc Casting Process

doi: 10.1109/JAS.2023.123777
Funds:  This work was supported in part by the National Major Scientific Research Equipment of China (61927803), the National Natural Science Foundation of China Basic Science Center Project (61988101), Science and Technology Innovation Program of Hunan Province (2021RC4054), and the China Postdoctoral Science Foundation (2021M691681)
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  • The copper disc casting machine is core equipment for producing copper anode plates in the copper metallurgy industry. The copper disc casting machine casting package motion curve (CPMC) is significant for precise casting and efficient production. However, the lack of exact casting modeling and real-time simulation information severely restricts dynamic CPMC optimization. To this end, a liquid copper droplet model describes the casting package copper flow pattern in the casting process. Furthermore, a CPMC optimization model is proposed for the first time. On top of this, a digital twin dual closed-loop self-optimization application framework (DT-DCS) is constructed for optimizing the copper disc casting process to achieve self-optimization of the CPMC and closed-loop feedback of manufacturing information during the casting process. Finally, a case study is carried out based on the proposed methods in the industrial field.

     

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    Highlights

    • A liquid copper droplet model is presented to describe the liquid copper flow pattern of the casting package during the casting process. According to the relationship between the copper liquid level and the baffle in the casting package, the copper liquid flow in the casting process is defined as an open-channel hydraulic droplet and orifice outflow model. The model makes it possible to accurately describe the liquid copper outflow state in the casting package and the accumulation rate of liquid copper in the mold in the copper disc casting process
    • A CPMC objective function is constructed for the first time. The casting process is innovatively discretized into several sub-units, and the objective function set is established for each sub-unit with the casting process indicators as constraints and the maximization of the cast liquid copper quality per unit time as the optimization objective, which provides a critical basis for the solution of the optimal CPMC. Based on the proposed optimization method, the optimal CPMC solution is realized
    • A novel digital twin dual closed-loop self-optimization application framework for copper disc casting processes is proposed. Horizontal compliance with the base twin architecture paradigm is demonstrated and vertical compliance closely matches the characteristics of the specific application object. A dual closed-loop self-optimization process with five sub-modules is constructed. The closed-loop self-optimization and dynamic self-optimization of the digital twin model parameters are realized using real-time simulation data in a virtual space and manufacturing information in a physical space to ensure digital twin model reliability

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