A hybrid digital twin approach for proactive quality control in manufacturing

Abstract

Quality control is a critical aspect in today's fast-paced and competitive business landscape. The increasing digital transformation of manufacturing companies allows for the implementation of even proactive quality control strategies. This, however, requires the proper integration and analysis of shop floor data, regarding monitoring, diagnosis, and prognostics. This is to support defect recognition and recuperation, along with potential system reconfiguration based on knowledge extraction and human experience integration. Digital twins, being virtual replicas of physical assets, support real-time monitoring, analysis, and optimization. However, quality-related aspects may not be related to monitored parameters, thus solely data-driven models may not be accurate enough for proactive quality control. In this work, a hybrid digital twin is proposed, where data-driven models are used to finetune the behaviour of the digital twin based on its physics model. A use case concerning an industrial asset and the heat transfer to a steel bar is investigated with the results presented and commented on.