Augmented reality-based virtual-real fusion commissioning: a novel approach to production commissioning

The installation and commissioning of production units are crucial for establishing efficient production systems. However, current approaches frequently face challenges such as lengthy commissioning cycles, low productivity, and limited intelligence. This study aims to leverage the synergistic capabilities of augmented reality (AR) technology and digital twin technology in the context of Industry 4.0 to address the challenges faced in production commissioning. Therefore, to achieve intelligent commissioning, optimize the installation and commissioning process of production systems and increase productivity. This paper proposes a novel virtual-real fusion commissioning method utilizing AR for production commissioning. Initially, a digital twin modeling and process planning simulation method is introduced for virtual-real fusion production units; secondly, real-time commissioning and fusion display of the production process are enabled through AR technology; lastly, the approach is applied to the operation and commissioning of the motor rotor–embedded wire production unit. The results demonstrate that the system can simulate the entire production logic and operation even in the absence of certain equipment while visualizing the production process and product status. Furthermore, compared to traditional physical production commissioning, this method has achieved a 43.6% reduction in the commissioning cycle and resulted in space cost savings of 21.8%. Subsequent applications validate the soundness of the proposed modeling and fusion commissioning approach and provide practical theoretical and methodological guidance for digital twin modeling and production commissioning in production systems.