A Digital Twin Model of Three-Dimensional Shading for Simulation of the Ironmaking Process

Advanced manufacturing is a new trend for sustainable industrial development, and digital twin is a new technology that has attracted attention. Blast furnace smelting is an effective method in the manufacturing of iron and steel. Comprehensive and dependable surveillance of the blast furnace smelting process is essential for ensuring the smooth operation and improving of iron and steel output quality. The current technology makes it difficult to monitor the entire process of blast furnace ironmaking. Based on Unity 3D, this study presents a digital-twin virtual reality simulation system of blast furnace ironmaking. First, shading modeling creates a three-dimensional dynamic geometric model in different ironmaking system scenarios. Then, we script the animation and call particle system according to the motion mode of distinct geometric objects to give the dynamic effect of geometric objects. Shaders are the focus of the design and contributions. In addition, shader optimization technology can reduce hardware resource consumption and increase system fluency. Vertex shaders are used for all types of coordinate space transformation and vertex output; fragment shaders are used for texture sampling, light model calculation, normal calculation, noise superposition, and color output. The shader rendering technique allows for more realistic lighting effects. The presented dynamic digital twin system implements more realistic lighting analyzed in the ironmaking process. Virtual interaction logic’s design and deployment process is based on HTC VIVE hardware and VRTK toolkit. In the actual simulation process, the typical animation frame rate is stable at about 75 FPS (frames per second). The simulation system runs smoothly and a cutting-edge and state-of-the-art method for observing the blast furnace ironmaking process is suggested.