Digital Twin-driven machining process for thin-walled part manufacturing

Thin-walled parts are widely used in the aerospace, shipbuilding, and automotive industry, but due to its unique structure and high accuracy requirements, which leads to an increase in scrapped parts, high cost in production, and a more extended period in the trial machining process. However, to adapt to fast production cycles and increase the efficiency of thin-walled parts machining, this paper presents a Digital Twin-driven thin-walled part manufacturing framework to allow the machine operator to manage the product changes, make the start-up phases faster and more accurate. The framework has three parts: preparation, machining, and measurement, driven by Digital Twin technologies in detail. By establishing and updating the workpiece Digital Twin under a different status, various manufacturing information and data can be integrated and available to machine operators and other Digital Twins. It can serve as a guideline for establishing the machine tool and workpiece Digital Twin and integrating them into the machining process. It provides the machine operator opportunities to interact with both the physical manufacturing process and its digital data in real-time. The digital representation of the physical process can support them to manage the trial machining from different aspects. In addition, a demonstrative case study is presented to explain the implementation of this framework in a real manufacturing environment.     

DT-II:Digital twin enhanced Industrial Internet reference framework towards smart manufacturing

In this paper, the interplay and relationship between digital twin and Industrial Internet are discussed at first. The sensing/transmission network capability, which is one of the main characteristics of Industrial Internet, can be a carrier for providing digital twin with a means of data acquisition and transmission. Conversely, with the capability of high-fidelity virtual modeling and simulation computing/analysis, digital twin evolving from lifecycle management for a single product to application in production/manufacturing in the shop-floor/enterprise, can further greatly enhance the simulation computing and analysis of Industrial Internet. This paper proposes a digital twin enhanced Industrial Internet (DT-II) reference framework towards smart manufacturing. To further illustrate the reference framework, the implementation and operation mechanism of DT-II is discussed from three perspectives, including product lifecycle level, intra-enterprise level and inter-enterprise level. Finally, steam turbine is taken as an example to illustrate the application scenes from above three perspectives under the circumstance of DT-II. The differences between with and without DT-II for design and development of steam turbine are also presented.     

Digital twin-based designing of the configuration,motion, control,and optimization model of a flow-type smart manufacturing system

Digital twins can achieve hardware-in-the-loop simulation of both physical equipment and cyber model, which could be used to avoid the considerable cost of manufacturing system reconfiguration if the design deficiencies are found in the deployment process of the traditional irreversible design approach. Based on the digital twin technology, a quad-play CMCO (i.e., Configuration design-Motion planning-Control development-Optimization decoupling) design architecture is put forward for the design of the flow-type smart manufacturing system in the Industry 4.0 context. The iteration logic of the CMCO design model is expounded. Two key enabling technologies for enabling the customized and software-defined design of flow-type smart manufacturing systems are presented, including the generalized encapsulation of the quad-play CMCO model and the digital twin technique. A prototype of a digital twin-based manufacturing system design platform, named Digital Twin System, is presented based on the CMCO model. The digital twin-based design platform is verified with a case study of the hollow glass smart manufacturing system. The result shows that the Digital Twin System-based design approach is feasible and efficient.     

Digital twins-based smart manufacturing system design in Industry 4.0: A review

A smart manufacturing system (SMS) is a multi-field physical system with complex couplings among various components. Usually, designers in various fields can only design subsystems of an SMS based on the limited cognition of dynamics. Conducting SMS designs concurrently and developing a unified model to effectively imitate every interaction and behavior of manufacturing processes are challenging. As an emerging technology, digital twins can achieve semi-physical simulations to reduce the vast time and cost of physical commissioning/reconfiguration by the early detection of design errors/flaws of the SMS. However, the development of the digital twins concept in the SMS design remains vague. An innovative Function-Structure-Behavior-Control-Intelligence-Performance (FSBCIP) framework is proposed to review how digital twins technologies are integrated into and promote the SMS design based on a literature search in the Web of Science database. The definitions, frameworks, major design steps, new blueprint models, key enabling technologies, design cases, and research directions of digital twins-based SMS design are presented in this survey. It is expected that this survey will shed new light on urgent industrial concerns in developing new SMSs in the Industry 4.0 era.     

The HORSE framework: A reference architecture for cyber-physical systems in hybrid smart manufacturing

In the Industry 4.0 era, manufacturers strive to remain competitive by using advanced technologies such as collaborative robots, automated guided vehicles, augmented reality support and smart devices. However, only if these technological advancements are integrated into their system context in a seamless way, they can deliver their full potential to a manufacturing organization. This integration requires a system architecture as a blueprint for positioning and interconnection of the technologies. For this purpose, the HORSE framework, resulting from the HORSE EU H2020 project, has been developed to act as a reference architecture of a cyber-physical system to integrate various Industry 4.0 technologies and support hybrid manufacturing processes, i.e., processes in which human and robotic workers collaborate. The architecture has been created using design science research, based on well-known software engineering frameworks, established manufacturing domain standards and practical industry requirements. The value of a reference architecture is mainly established by application in practice. For this purpose, this paper presents the application and evaluation of the HORSE framework in 10 manufacturing plants across Europe, each with its own characteristics. Through the physical deployment and demonstration, the framework proved its goal to be basis for the well-structured design of an operational smart manufacturing cyber-physical system that provides horizontal, cross-functional management of manufacturing processes and vertical control of heterogeneous technologies in work cells. We report on valuable insights on the difficulties to realize such systems in specific situations. The experiences form the basis for improved adoption, further improvement and extension of the framework. In sum, this paper shows how a reference architecture framework supports the structured application of Industry 4.0 technologies in manufacturing environments that so far have relied on more traditional digital technology.     

Digital twin-driven service model and optimal allocation of manufacturing resources in shared manufacturing

The sharing economy has been recognized a mutually beneficial economic mode. Deriving from the concept of sharing economy, shared manufacturing was proposed under the support of advanced information and manufacturing technologies. As a core part of implementing shared manufacturing, manufacturing resource allocation aims to coordinate cross-organizational resources to provide on-demand services for personalized manufacturing requirements. However, some challenges still hinder effective and efficient resource allocation in shared manufacturing. Traditional centralized optimization methods with only one decision model are difficult to maintain autonomous decision rights of resource providers. Thus, they could hardly adapt to the situation of cross-organizational resource coordination. In addition, the credit of resource providers is rarely considered in the resource allocation process, which is unfavorable for promoting more reliable trades in shared manufacturing. To address these issues, this study proposes an integrated architecture to promote the resource allocation in shared manufacturing. A digital twin-driven service model is built to perform the seamless monitoring and control of shared manufacturing resources. The resource allocation model is constructed based on the consideration of the credit of resource providers. To keep the decision autonomy of resource providers, augment Lagrangian coordination is adopted to analyze the constructed resource allocation model. A case study is further employed to validate the effectiveness and efficiency of the proposed method in performing the resource allocation in shared manufacturing.     

Ensemble sparse supervised model for bearing fault diagnosis in smart manufacturing

Machinery fault diagnosis is of great significance to improve the reliability of smart manufacturing. Deep learning based fault diagnosis methods have achieved great success. However, the features extracted by different models may vary resulting in ambiguous representation of the data, and even wasted time with manually selecting the optimal hyperparameters. To solve the problems, this paper proposes a new framework named Ensemble Sparse Supervised Model (ESSM), in which a typical deep learning model is treated as two phases of feature learning and model learning. In the feature learning phase, the original data is represented to be a feature matrix as non-redundant as possible by applying sparse filtering. Then, the feature matrix is fed into the model learning phase. Regularization, dropout and rectified linear unit (ReLU) are used in the model's neurons and layers to build a sparse deep neural network. Finally, the output of the sparse deep neural network provides feedback to the first phase to obtain better sparse features. In the proposed method, hyperparameters need to be pre-specified and a python library of talos is employed to finish the process automatically. The proposed method is verified using the bearing data provided by Case Western Reserve University. The result demonstrates that the proposed method can capture the effective pattern of data with the help of sparse constraints and simultaneously provide convenience for the operators with assuring performance.     

Taxonomy,technology and applications of smart objects

Deployment of embedded technologies is increasingly being examined in industrial supply chains as a means for improving efficiency through greater control over purchase orders, inventory and product related information. Central to this development has been the advent of technologies such as bar codes, Radio Frequency Identification (RFID) systems, and wireless sensors which when attached to a product, form part of the product’s embedded systems infrastructure. The increasing integration of these technologies dramatically contributes to the evolving notion of a “smart product”, a product which is capable of incorporating itself into both physical and information environments. The future of this revolution in objects equipped with smart embedded technologies is one in which objects can not only identify themselves, but can also sense and store their condition, communicate with other objects and distributed infrastructures, and take decisions related to managing their life cycle. The object can essentially “plug” itself into a compatible systems infrastructure owned by different partners in a supply chain. However, as in any development process that will involve more than one end user, the establishment of a common foundation and understanding is essential for interoperability, efficient communication among involved parties and for developing novel applications. In this paper, we contribute to creating that common ground by providing a characterization to aid the specification and construction of “smart objects” and their underlying technologies. Furthermore, our work provides an extensive set of examples and potential applications of different categories of smart objects.     

Fundamentals of smart manufacturing: A multi-thread perspective

The paper outlines key characteristics of smart manufacturing, data-driven, networked, connected, resource sharing, resilient, and sustainable. Manufacturing resiliency and sustainability have received limited attention in the literature and they are the focus of this paper. Both are related and offer challenges that may become differentiators of smart manufacturing. Resiliency provides businesses with defenses against natural and human caused adversities. The list of attributes provided in the paper is intended for comprehensive assessment of manufacturing resiliency. Solutions are needed to make businesses more resilient and sustainable. Research on business models equating sustainability with an industrial activity is suggested. A scheme for labeling environmental friendliness of materials makes as a token contribution to sustainability.     

Service-oriented smart home applications: composition, code generation, deployment, and execution

A smart home usually has a variety of devices or home appliance, instead of designing software for a specific home, this paper proposes a service-oriented framework with a set of ontology systems to support service and device publishing, discovery of devices and their services, composition of control software using existing control services that wrap devices, deployment, and execution of the composed service in an computing environment, monitoring the execution, and recovery from device failure. The ontology systems specify semantic information about devices, services, and workflows used in various smart home, and users can compose and recompose services for their specific needs. New devices, workflows, and services can be added into ontology. Most of the steps in this process can be automated including code generation. For example, service composition will be carried out in three steps: abstract workflow design, function construction, and device discovery, and different codes can be generated for different computing platforms such as Java and Open Services Gateway initiative environments. In this way, a variety of smart home can be constructed rapidly using the framework by discovery and composition using existing services and workflows. This paper illustrates this framework using a media control example to illustrate the ontology, discovery, composition, deployment, execution, monitoring, and recovery.     

SOAdapt: A process reference model for developing adaptable service-based applications

Context

The loose coupling of services and Service-Based Applications (SBAs) have made them the ideal platform for context-based run-time adaptation. There has been a lot of research into implementation techniques for adapting SBAs, without much effort focused on the software process required to guide the adaptation.

Objective

This paper aims to bridge that gap by providing an empirically grounded software process model that can be used by software practitioners who want to build adaptable SBAs. The process model will focus only on the adaptation specific issues.

Method

The process model presented in this paper is based on data collected through interviews with 10 practitioners occupying various roles within eight different companies. The data was analyzed using qualitative data analysis techniques. We used the output to develop a set of activities, tasks, stakeholders and artifacts that were used to construct the process model.

Results

The outcome of the data analysis process was a process model identifying nine sets of adaptation process attributes. These can be used in conjunction with an organisation’s existing development life-cycle or another reference life-cycle.

Conclusion

The process model developed in this paper provides a solid reference for practitioners who are planning to develop adaptable SBAs. It has advantages over similar approaches in that it focuses on software process rather than the specific adaptation mechanism implementation techniques.     

Software reference architecture for smart environments: Perception

With the increase of intelligent devices, ubiquitous computing is spreading to all scopes of people life. Smart home (or industrial) environments include automation and control devices to save energy, perform tasks, assist and give comfort in order to satisfy specific preferences.This paper focuses on the proposal for Software Reference Architecture for the development of smart applications and their deployment in smart environments. The motivation for this Reference Architecture and its benefits are also explained. The proposal considers three main processes in the software architecture of these applications: perception, reasoning and acting.This paper centres attention on the definition of the Perception process and provides an example for its implementation and subsequent validation of the proposal.The software presented implements the Perception process of a smart environment for a standard office, by retrieving data from the real world and storing it for further reasoning and acting processes. The objectives of this solution include the provision of comfort for the users and the saving of energy in lighting. Through this verification, it is also shown that developments under this proposal produce major benefits within the software life cycle.     

Future directions and research issues for ergonomics and advanced manufacturing technology (AMT)

In recent years, great progress has been made in the development of computer-based technologies that support the manufacturing industries. Those concerned with advanced manufacturing technology (AMT) are becoming increasingly aware of the fundamental importance of human organisational issues for the successful development, implementation, operation and maintenance of AMT. The discipline of industrial ergonomics and occupational occupational psychology, therefore, have a significant contribution to make in this field. This paper introduces the special issue, Ergonomics Matters in AMT, and presents a discussion of some of the future directions of AMT and the likely implications for ergonomics research.     

A reference model for deploying applications in virtualized environments

Modern scientific research has been revolutionized by the availability of powerful and flexible computational infrastructure. Virtualization has made it possible to acquire computational resources on demand. Establishing and enabling use of these environments is essential, but their widespread adoption will only succeed if they are transparently usable. Requiring changes to applications being deployed or requiring users to change how they utilize those applications represent barriers to the infrastructure acceptance. The problem lies in the process of deploying applications so that they can take advantage of the elasticity of the environment and deliver it transparently to users. Here, we describe a reference model for deploying applications into virtualized environments. The model is rooted in the low‐level components common to a range of virtualized environments and it describes how to compose those otherwise dispersed components into a coherent unit. Use of the model enables applications to be deployed into the new environment without any modifications, it imposes minimal overhead on management of the infrastructure required to run the application, and yields a set of higher‐level services as a byproduct of the component organization and the underlying infrastructure. We provide a fully functional sample application deployment and implement a framework for managing the overall application deployment. Copyright © 2011 John Wiley & Sons, Ltd.     

Information field in a manufacturing System: Concepts,measurements and applications

As the core of the Industry 4.0 era, information can improve the efficiency of production as well as bring cognitive load to operators. In this study, we aim to develop a unified information field analysis model for manufacturing systems and to estimate the cognitive load of operators through the action features of the information field. The qualitative and quantitative analytical framework model of the information field in manufacturing systems is established using information entropy and fuzzy mathematics. Furthermore, the cognitive load mechanism in manufacturing systems is clarified. The information principles that must be exercised to improve and optimise manufacturing systems under the information field framework are proposed for implementing lean production and digital transformation. Results of a case study show that the proposed information field analysis model for manufacturing systems reveal the change law of information field of manufacturing system in time and space, which has considerable guiding values for enhancing the management efficiency of shop floors and the sustainable development of enterprises.     

A survey of model reference adaptive techniques—Theory and applications

Model Reference Adaptive Systems have been used more and more widely in the last few years to solve various control, parameter identification and state estimation problems. This survey paper tries to present in a systematic way the “state of the art” based on the literature published since 1964, 253 references. Attention is paid to the basic properties and the classification of various types of model reference adaptive systems. The most prominent design methods are reviewed; unresolved questions and future areas of investigation are also discussed. A survey of the applications already accomplished and those which appear feasible in the near future conclude the paper.     

Appropriate technology for manufacturing: Some management issues

This paper introduces the idea of appropriate technology and applies it to the choices organisations make when designing, implementing and managing advanced manufacturing technologies. Five sets of choices are considered: the type and level of technology; the allocation of functions between humans and machines; the role of humans in advanced systems; the organisation structures to support them; and the ways in which people participate in their design. The paper concludes that most organisations are not effective at developing and implementing appropriate technologies, and that ergonomists have failed to meet the needs of technologies and managers in these areas.