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<p>To address the inefficiencies inherent in traditional steel structure welding processes and to achieve real-time operational visualization, this study presents the design of a digital twin visualization system specifically tailored for steel structure welding. The system integrates a physical welding platform with a high-fidelity virtual model, establishing a bidirectional synchronization mechanism through Modbus TCP/IP communication between the physical PLC and the virtual environment. A multi-layered architecture, encompassing physical, virtual, data, service, and application layers, is employed to facilitate real-time data mapping, dynamic monitoring, and collaborative optimization. By leveraging NX MCD and TIA Portal, a bidirectional signal adapter is utilized to promote seamless interaction between virtual simulations and physical operations, significantly reducing programming cycles and mitigating on-site debugging risks. Experimental validation conducted in an industrial workshop demonstrates that, compared to conventional methods, the proposed approach enhances welding path planning efficiency by 31.25 %. Furthermore, the digital twin framework improves welding positioning accuracy, achieving a qualification rate of 98.2 %, thereby ensuring robust synchronization between virtual predictions and physical outcomes. This work provides a scalable solution for intelligent welding control, offering significant advancements in production efficiency, operational safety, and process stability for complex steel structure manufacturing.</p>

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Design of a visualization system for steel structure welding based on digital twin technology

  • 期刊论文

  • 发表日期：

    2025年8月4日

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  • Shuqiang Wang,
  • Junwei Li,
  • Kuan Zhang,
  • Wei Lu,
  • Jiawen Tian

摘要

To address the inefficiencies inherent in traditional steel structure welding processes and to achieve real-time operational visualization, this study presents the design of a digital twin visualization system specifically tailored for steel structure welding. The system integrates a physical welding platform with a high-fidelity virtual model, establishing a bidirectional synchronization mechanism through Modbus TCP/IP communication between the physical PLC and the virtual environment. A multi-layered architecture, encompassing physical, virtual, data, service, and application layers, is employed to facilitate real-time data mapping, dynamic monitoring, and collaborative optimization. By leveraging NX MCD and TIA Portal, a bidirectional signal adapter is utilized to promote seamless interaction between virtual simulations and physical operations, significantly reducing programming cycles and mitigating on-site debugging risks. Experimental validation conducted in an industrial workshop demonstrates that, compared to conventional methods, the proposed approach enhances welding path planning efficiency by 31.25 %. Furthermore, the digital twin framework improves welding positioning accuracy, achieving a qualification rate of 98.2 %, thereby ensuring robust synchronization between virtual predictions and physical outcomes. This work provides a scalable solution for intelligent welding control, offering significant advancements in production efficiency, operational safety, and process stability for complex steel structure manufacturing.