Design of automatic spray monitoring and tele-operation system based on digital twin technology

To solve the problems of low degree of automation, difficulty in quality control and poor working environment during the process of spray-painting rotational parts, this paper designs an automatic spray monitoring and tele-operation system based on digital twin technology, which can realize real-time monitoring and tele-operation fault treatment during the spraying process to achieve the goal of “man-machine isolation”. First, an automatic production line for spraying operations is designed in which the spraying equipment can be remotely controlled. Then, multiple sensors are used to collect the environmental and equipment conditions. After that, multisource heterogeneous data are pretreated to construct a unified data template and interfaces. On this basis, a three-dimensional model of the environment and equipment is established. According to the fusion and mapping between sensor data and the geometric model, an augmented reality twin model of spray painting is obtained. Additionally, the relevant support database and knowledge base are established; a fault diagnosis method based on knowledge is proposed to provide support for fault treatment. Finally, an automatic spraying monitoring and tele-operation software platform is developed that can run under monitoring or tele-operation mode, and the related functions are tested and verified. The test results show that the system is more efficient than manual spraying method, and the coating surfaces is flatter, effectively reducing the probability of sagging, orange peel, missing spray and other problems. This research provides a reference for the design and construction of automatic spraying production lines.