Digital twin enabled optimal reconfiguration of the semi-automatic electronic assembly line with frequent changeovers

Abstract

• This paper proposes a digital twin enabled optimal reconfiguration approach of semi-automatic electronic assembly line with frequent changeovers. The contributions can be summarized as following: • A digital twin enabled reconfiguration assembly mode and its related reconfiguration & operation platform are developed for electronic products assembly. • An open architecture in equipment and line levels is developed to support the rapid physical reconfiguration. • A generalized knowledge encapsulation technique is constructed to speed up the procedure of virtual reconfiguration. • An optimal reconfiguration algorithm via analytical target cascading, named minimal reconfiguration (MR), is proposed to solve the coupled optimization of order scheduling, line balancing, and buffer allocation. The survival of original equipment manufacturers (OEMs) requires rapid responses to changing customer demands while keeping cost savings as their top priority. This paper proposes a Digital Twin (DT) enabled reconfiguration framework for the semi-automatic electronic assembly line with frequent changeovers. The DT platform develops an open architecture for the equipment and the assembly line to support its rapid physical reconfiguration, and a generalized knowledge encapsulation technique is applied to facilitate virtual reconfiguration. The dynamic performance is evaluated by max-plus semiring. Subsequently, an optimal reconfiguration algorithm via analytical target cascading, named minimal reconfiguration, is proposed to solve the coupled optimization of order scheduling, line balancing, and buffer allocation. A smart-phone assembly line is applied to verify the DT platform efficiency and minimal reconfiguration optimization approach.