本文针对新能源汽车生产线“三电”系统集成复杂、传统物理调试周期长、成本高、效率低等问题，本文提出一种基于数字孪生的新能源汽车生产线虚拟调试方法，构建“物理实体—虚拟孪生—数据交互”3层集成架构，实现四大工艺全流程数字化映射；创新多源数据融合引擎，建立工艺优化与误差补偿模型，并形成“预仿真—联调—优化”三级虚拟调试流程。经某头部车企产线验证：工艺优化周期由 3~6 周缩短至 72 h，质量追溯时间由 2~4 h 压缩至 8 min，缺陷分析准确率达 92%~95%，产线综合能效与产品合格率显著提升。该方法可为新能源汽车智能制造提供可落地、可复制的技术路径。

In response to the complex integration of "three-in-one" systems in the production line of new energy vehicles, the long traditional physical debugging cycle, high cost, and low efficiency, a virtual debugging method for the production line of new energy vehicles based on digital twin is proposed. A three-layer integrated architecture of "physical entity-virtual twin-data interaction" is constructed to realize the digital mapping of the entire process of four major processes; an innovative multi-source data fusion engine is established to build a process optimization and error compensation model, and a three-level virtual debugging process of "pre-simulation-joint debugging-optimization" is formed. After verification on the production line of a leading automaker: the process optimization cycle is shortened from 3 to 6 weeks to 72 hours, the quality traceability time is compressed from 2 to 4 hours to 8 minutes, the accuracy of defect analysis reaches 92% to 95%, and the comprehensive energy efficiency and product qualification rate of the production line have been significantly improved. This method can provide a feasible and replicable technical path for the intelligent manufacturing of new energy vehicles.