Development of a Cloud Platform for Laser Cladding Based on Digital Twin

Abstract

To address the issues in traditional laser cladding systems—such as reliance on manual experience for process parameters, severe data silos, and the lack of real-time monitoring and closed-loop control—this study develops an intelligent manufacturing cloud platform system based on Digital Twin (DT) technology. Firstly, a parametric virtual simulation environment is established by developing custom process components within the Siemens Plant Simulation DT platform. Secondly, real-time data interaction between Plant Simulation and the underlying PLC is achieved via the OPC UA protocol, enabling millisecond-level data acquisition from physical equipment and synchronization with the virtual model. Finally, the self-developed Industrial Internet cloud platform is integrated using the MQTT protocol, resulting in a cloud system comprising three core modules: equipment management, real-time monitoring, and historical data traceability. This research realizes full-process data integration and real-time interaction among physical equipment, the digital twin, and the cloud platform. The developed cloud platform enables remote, real-time status monitoring and visualization of the laser cladding process, thereby providing critical technical support for intelligent process optimization and cross-regional collaborative management.