Abstract: In order to solve the problem of long cycle and high cost of production line designing and commissioning, the commissioning method and its application in manufacturing systems are studied. According to the characteristics of each method, a digital twins-based distributed approximate physical integrated commissioning method for production lines is proposed by integrating hardware-in-loop, software-in-loop and equipment-in-loop technology. Through establishing digital twins model for physical entities during the design phase, this method can conduct commissioning of production lines with virtual commissioning for the design scheme, semi-physical commissioning for the controller and equipment-in-loop commissioning for the synchronization of virtuality and reality. Also, it supports sectional no-load integrated commissioning for multiple suppliers' equipment to improve the commissioning and validation processes of remote equipment and production line control logic during the integration process of intelligent workshop production lines. Finally, the effectiveness of the method is verified based on a digital twins system (DTS) through a case of a motor assembly line.

Key words: digital twins, distributed, approximate physical simulation, integrated commissioning