Digital Twin Visualization Design for Intelligent Warehousing and AGV Scheduling System

Abstract

To address information silos, delayed equipment-state perception, path conflicts among multiple AGVs, and insufficient visual monitoring capability in conventional warehousing systems, this paper proposes a digital-twin-based visualization design method for an intelligent warehousing and AGV scheduling system. First, three-dimensional models of key equipment, including the automated storage warehouse, underride AGVs, racks, inbound/outbound stations, and handling manipulators, are constructed using the three-dimensional modeling platform, and non-critical structures are lightweighted to balance visualization accuracy and simulation efficiency. Second, rigid bodies, collision bodies, motion joints, sensors, actuators, and signal mapping relationships are configured in the NX_MCD mechatronic concept design environment to establish a virtual warehousing system with kinematic constraints and logical response capability. Third, a virtual PLC control system is developed by integrating TIA Portal and PLCSIM Advanced, enabling real-time signal interaction between the PLC control program and the NX_MCD simulation model. On this basis, virtual commissioning of AGV storage and retrieval paths, manipulator handling actions, and inbound/outbound operation processes is realized. Finally, an HMI interface is used to dynamically monitor and visualize rack occupancy, AGV operating status, and inbound/outbound task information. The results show that the proposed method can achieve coordinated mapping among physical objects, control logic, and virtual models in an intelligent warehousing system. It provides a feasible engineering solution for multi-AGV scheduling process verification, warehouse operation monitoring, and early-stage virtual commissioning, and offers practical reference for reducing physical commissioning costs, improving warehouse system design efficiency, and promoting the digital transformation of small- and medium-sized warehousing systems.