Real-time Evaluation Method for Production Safety Risks Based on Digital Twin

doi:10.3901/JME.2025.12.315

Abstract

Abstract: In the automated production of dangerous products, equipment failures and other exceptional situations can lead to risk accidents. Therefore, effective real-time risk assessment based on on-site condition monitoring is crucial to prevent personnel injuries and reduce property losses. Firstly, the workshop's real-time risks are characterized from the perspective of spatiotemporal cross-analysis. Secondly, based on this real-time risk characterization, a comprehensive framework for real-time risk assessment in a digital twin environment that integrates physical modeling, mapping, and pre-simulation is constructed. Utilizing an agent-based modeling approach, the risk factors-state environment, disaster events, and vulnerable entities-are modeled separately. The interaction logic between multi-source data and accident mechanisms within these three spatial dimensions is designed in detail. Finally, the proposed method is applied in a specific pyrotechnic product production unit, demonstrating its effectiveness in practical application scenarios. This method integrates information across multiple dimensions, including production behavior, equipment status, and environmental conditions, enabling real-time risk assessment. It overcomes the limitations of traditional methods and explores new technological pathways for autonomous low-risk production of pyrotechnic products, providing technical support for the realization of dark factory environments.

Key words: real-time risk assessment, digital twin, agent-based model, production safety

CLC Number:

TJ05

YUAN Tangxiao, WU Qinqin, LIU Linyan, WANG Huifen, TIAN Shuang. Real-time Evaluation Method for Production Safety Risks Based on Digital Twin[J]. Journal of Mechanical Engineering, 2025, 61(12): 315-326.

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