用数学模型让金属成形机器人自动调参,实时适应材料变化。
Adaptive Digital Twin of Sheet Metal Forming via Proper Orthogonal Decomposition-Based Koopman Operator with Model Predictive Control
- 用POD和柯普曼算子降维建模,把复杂变形过程转为可计算的线性形式。
- 通过在线递归最小二乘法实时更新模型,实现动态自适应控制。
- 适用于机器人成形等非线性制造场景,适合想做智能产线的工程师。
数字孪生(DT)技术正推动制造业向实时预测、监控与控制演进。然而,在依赖变形的金属成形中,仍面临时空强耦合与工艺路径和材料响应间非线性关系的挑战。例如,人工依赖性强的滚轮成形工艺至今缺乏能自主规划与调整成形策略的数字孪生系统。本研究提出一种自适应数字孪生框架,结合本征正交分解(POD)进行物理感知降维,利用柯普曼算子将非线性系统映射至线性升维空间,支持基于模型预测控制(MPC)的实时决策。为适应过程条件或材料状态变化,引入在线递归最小二乘(RLS)算法,实时更新算子系数,实现新变形数据下的持续模型自适应。该框架在机器人滚轮成形系统上实验验证,测量并建模了不同工具路径下的变形场。结果表明,该自适应数字孪生能够有效捕捉非稳态过程行为,实现目标形状的精准控制。除该案例外,该框架为非线性制造系统的可解释、自适应、计算高效数字孪生提供了通用方法,连接了降阶物理表示与数据驱动适应性,支撑自主工艺控制与优化。
原文摘要 · Abstract (English)
Digital Twin (DT) technologies are transforming manufacturing by enabling real-time prediction, monitoring, and control of complex processes. Yet, applying DT to deformation-based metal forming remains challenging because of the strongly coupled spatial-temporal behavior and the nonlinear relationship between toolpath and material response. For instance, sheet-metal forming by the English wheel, a highly flexible but artisan-dependent process, still lacks digital counterparts that can autonomously plan and adapt forming strategies. This study presents an adaptive DT framework that integrates Proper Orthogonal Decomposition (POD) for physics-aware dimensionality reduction with a Koopman operator for representing nonlinear system in a linear lifted space for the real-time decision-making via model predictive control (MPC). To accommodate evolving process conditions or material states, an online Recursive Least Squares (RLS) algorithm is introduced to update the operator coefficients in real time, enabling continuous adaptation of the DT model as new deformation data become available. The proposed framework is experimentally demonstrated on a robotic English Wheel sheet metal forming system, where deformation fields are measured and modeled under varying toolpaths. Results show that the adaptive DT is capable of controlling the forming process to achieve the given target shape by effectively capturing non-stationary process behaviors. Beyond this case study, the proposed framework establishes a generalizable approach for interpretable, adaptive, and computationally-efficient DT of nonlinear manufacturing systems, bridging reduced-order physics representations with data-driven adaptability to support autonomous process control and optimization.
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