Abstract

Adoption of digital twins in smart factories, that model real statuses of manufacturing systems through simulation with real time actualization, are manifested in the form of increased productivity, as well as reduction in costs and energy consumption. The sharp increase in changing customer demands has resulted in factories transitioning rapidly and yielding shorter product life cycles. Traditional modeling and simulation approaches are not suited to handle such scenarios. As a possible solution, we propose a generic data-driven framework for automated generation of simulation models as basis for digital twins for smart factories. The novelty of our proposed framework is in the data-driven approach that exploits advancements in machine learning and process mining techniques, as well as continuous model improvement and validation. The goal of the framework is to minimize and fully define, or even eliminate, the need for expert knowledge in the extraction of the corresponding simulation models. We illustrate our framework through a case study.

Highlights

  • Over the years, several definitions of the term “digital twin” have been proposed (Grieves, 2015)

  • The novelty of the proposed framework lies in the fact that we utilize the advancements in machine learning and process mining to overcome the drawbacks of previous approaches in automatic/semi-automatic simulation model devel­ opment, and to build data-driven models that are continuously va­ lidated and updated

  • We present a case study of assembling a quad­ copter drone part in order to motivate and point out the possibilities of data-driven simulation modeling for digital twins in robot with a robot arm that can load, transport and unload items, 3) A high-speed assembly track with magnetically attached transport devices, 4) Two assembly cells equipped with collaborative robot arms capable of carrying out specific tasks, and 5) A human machine interface (HMI) for controlling and monitoring the production pro­ cess (Jepsen et al, 2020)

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Summary

Introduction

Several definitions of the term “digital twin” have been proposed (Grieves, 2015). We consider the case of data-driven digital twin modeling for smart manufacturing. The previous works on automatic or semi-automatic simulation modeling range from knowledge/data driven to event modeling approaches These works utilize different kinds of data and manufacturing scenarios. The focus of our work is on Product Life Cycle (PLC) in the context of reconfigurable manufacturing systems This leads us to the following relevant challenges: 1) Entire PLC management: all aspects of a product lifecycle, com­ mencing from its design/idea conception to its sale can be han­ dled by specialized digital twins (Kritzinger et al, 2018), (Lattner et al, 2010). We develop a framework for data-driven digital twins for smart manufacturing. This framework provides many ad­ vantages to deal with the current challenges of smart.

Background
Challenges with traditional simulation models
Data-driven simulation modeling
Digital twins for smart factories
Data-driven digital twins for smart factories
Key elements of data-driven digital twins
Framework for data-driven digital twins
Smart manufacturing facility for the case study
Production line description
Case study
Reliability simulation model
Data-driven reliability and simulation modeling
Practical Demonstration
Conclusion
Full Text
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