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.     

A generic tri-model-based approach for product-level digital twin development in a smart manufacturing environment

Smart manufacturing, as an emerging manufacturing paradigm, leverages massive in-context data from manufacturing systems for intelligent decision makings. In such context, Cyber-Physical Systems (CPS) play a key role in digitizing manufacturing systems and integrating multiple systems together for collaborative works. Amongst different levels of smartness and connectedness of CPS, Digital Twin (DT), as an exact digital copy of a physical object or system including its properties and relationship with the environment, has a significant impact on realizing smart manufacturing. A DT constantly synchronizes with its physical system and provides real-time high-fidelity simulations of the system and offers ubiquitous control over the system. Despite its great advantages, few works have been discussed about DT reference models, let alone a generic manner to establish it for smart manufacturing. Aiming to fill the gap, this research introduces a generic CPS system architecture for DT establishment in smart manufacturing with a novel tri-model-based approach (i.e. digital model, computational model and graph-based model) for product-level DT development. The tri-model works concurrently to simulate real-world physical behaviour and characteristics of the digital model. To validate the proposed architecture and approach, a case study of an open source 3D printer DT establishment is further conducted. Conclusions and future works are also highlighted to provide insightful knowledge to both academia and industries at last.     

Modular machine tools: Design and barriers to industrial implementation

The Reconfigurable Manufacturing System (RMS) paradigm has been developed to address challenges in the design of manufacturing systems and equipment that will meet the demands of modern manufacturing. This research involved the development of Modular Reconfigurable Machines (MRMs); as an emerging technology in reconfigurable manufacturing. MRMs are mechanically modular machines. The modularity permits the kinematic architecture and processing functions of the machine to be reconfigured to meet changing production requirements. This paper will focus on aspects of the mechanical design and the development of a control system that supported the modularity and reconfigurability of the mechanical platform. A modular electronic system is presented that is characterized by a plug and play approach to control scalability. This is complemented by a software architecture that has been developed with a focus on hardware abstraction for the management of an augmented mechanical and electronic architecture. The implications of MRMs for RMSs are discussed and key inhibitors to industrial implementation are identified.     

基于多智能体的数字孪生及其在工业中应用的综述

数字孪生是一种将物理实体数字化的技术,通过建立虚拟的数字孪生模型模拟实际的物理过程,以便进行模拟仿真、数据分析和优化设计等操作.鉴于此,分析数字孪生技术在复杂工业生产中的发展历程和研究现状,并重点讨论其概念、国家相关重点研究的政策,以及数字孪生使能技术在各行业的应用.主要途径是分析和综述基于多智能体的数字孪生、基于数字孪生的设计、制造和运维、数字孪生的集成在智能制造中的应用相关的研究成果.此外,提出高炉连续生产数字孪生方案和大飞机多智能体离散制造方案,高炉模型包括成分场大模型和增量学习小模型,该模型可以为数字孪生在复杂流程工业中的应用提供带有增量补偿的机理与计算机视觉相结合的解决方案.在复杂工业制造中,数字孪生和多智能体技术可以提高生产效率和质量,减少能源消耗和废品产生,同时也能够降低复杂度、安全风险和成本.     

A PC-based open robot control system: PC-ORC

An open architecture manufacturing system pursues to integrate manufacturing components on a single platform. Therefore, a particular component can be easily added and/or replaced. In this paper, a modular and object-oriented approach for the PC-based open robot control (PC-ORC) system is investigated. A standard reference model for controlling robots, which consists of a hardware platform, an operating system module, and various application software modules, is first proposed. Then, PC-ORC system, which can reconfigure the control system in various production environments, is developed. The PC-ORC is constructed based upon the object-oriented method. Hence, it allows an easy implementation and modification of various modules. The PC-ORC consists of basic software, application objects, and additional hardware devices on a PC platform. Finally, by applying the proposed PC-ORC to a SCARA robot, the performance of the PC-ORC is examined.     

A decision-making framework for dynamic scheduling of cyber-physical production systems based on digital twins

Nowadays, one important challenge in cyber-physical production systems is updating dynamic production schedules through an automated decision-making performed while the production is running. The condition of the manufacturing equipment may in fact lead to schedule unfeasibility or inefficiency, thus requiring responsiveness to preserve productivity and reduce the operational costs. In order to address current limitations of traditional scheduling methods, this work proposes a new framework that exploits the aggregation of several digital twins, representing different physical assets and their autonomous decision-making, together with a global digital twin, in order to perform production scheduling optimization when it is needed. The decision-making process is supported on a fuzzy inference system using the state or conditions of different assets and the production rate of the whole system. The condition of the assets is predicted by the condition-based monitoring modules in the local digital twins of the workstations, whereas the production rate is evaluated and assured by the global digital twin of the shop floor. This paper presents a framework for decentralized and integrated decision-making for re-scheduling of a cyber-physical production system, and the validation and proof-of-concept of the proposed method in an Industry 4.0 pilot line of assembly process. The experimental results demonstrate that the proposed framework is capable to detect changes in the manufacturing process and to make appropriate decisions for re-scheduling the process.     

A flexible data schema and system architecture for the virtualization of manufacturing machines (VMM)

Future factories will feature strong integration of physical machines and cyber-enabled software, working seamlessly to improve manufacturing production efficiency. In these digitally enabled and network connected factories, each physical machine on the shop floor can have its ‘virtual twin’ available in cyberspace. This ‘virtual twin’ is populated with data streaming in from the physical machines to represent a near real-time as-is state of the machine in cyberspace. This results in the virtualization of a machine resource to external factory manufacturing systems. This paper describes how streaming data can be stored in a scalable and flexible document schema based database such as MongoDB, a data store that makes up the virtual twin system. We present an architecture, which allows third-party integration of software apps to interface with the virtual manufacturing machines. We evaluate our database schema against query statements and provide examples of how third-party apps can interface with manufacturing machines using the VMM middleware. Finally, we discuss an operating system architecture for VMMs across the manufacturing cyberspace, which necessitates command and control of various virtualized manufacturing machines, opening new possibilities in cyber-physical systems in manufacturing.     

An Empirical Methodology for Exploring Reconfigurable Architectures

Recent research in reduced instruction set computer architectures has emphasized the importance of the empirical approach to designing computer architectures: architectural features are analyzed for utility and cost with respect to the system software that uses them. This approach has resulted in architectural simulators that allow computer designers to vary the features of the architecture being simulated and to analyze how the addition or removal of these features affects the cost and performance of the architecture. In this paper we apply this technique to a new area: reconfigurable architectures. Our approach is to use an empirical methodology that emphasizes the interaction between the target software and the reconfigurability features of parallel architectures. We have developed a set of tools, the reconfigurable architecture workbench, that assists in this methodology by allowing parallel programs to be simulated on a target architecture in order to study the performance implications of various reconfigurability features. The workbench is based on a framework, the PCI model, which describes the range of parallel programs, parallel architectures, and reconfiguration features. We present details of the design and implementation of a prototype workbench, GT-RAW. GT-RAW is being used to study the utility of one dimension of reconfiguration for image processing and image understanding applications. We present an example of the experiments that are being conducted with GT-RAW as a demonstration of our empirical methodology.     

Modeling and implementation of a digital twin of material flows based on physics simulation

Cyber-physical production systems enable adaptivity and flexibility when manufacturing customized products in small batches. Due to varying routes and a high variance of workpieces, material flows in cyber-physical production systems can get highly complex, which can lead to physically induced disturbances that can result in accidents or decreased throughput and high costs. This issue can be addressed by applying a physics engine to simulate the physical interaction between workpieces and the material handling systems during the operation. Connecting such a digital model to a real material handling system in order to derive simulation-based decision support leads to the concept of digital twins. To date, few practical implementations of digital twins in manufacturing outside the machine tool domain were reported. Therefore, this paper describes the modeling and the subsequent implementation of an integrated system that consists of a real material handling system and its digital twin, based on physics simulation. A practical use case demonstrates the versatile advantages of the implemented solution for a manufacturing system with respect to the three digital twin functions prediction, monitoring and diagnosis.     

基于设计模式的星载软件体系结构设计方法

星载软件是整个卫星系统设计和开发的中心,而体系结构是整个软件开发的蓝图,在软件开发中占有十分重要的位置。为了提高星载软件开发效率,降低研制成本,同时满足实时性、可重构和可维护性要求,从体系结构的前3个视图方面采用基于设计模式的方法提出了一种满足要求的星载软件体系结构。     

The model-based product agent: A control oriented architecture for intelligent products in multi-agent manufacturing systems

The multi-agent control strategy has been previously shown to improve the flexibility of complex, dynamic manufacturing systems. One key component of this strategy is the product agent. The product agent is responsible for autonomously guiding a physical part in the manufacturing system based on its production goals. Though the product agent has been described in previous works, a fully developed software architecture for the product agent that uses a model-based optimization approach has not been proposed. In this work, a product agent architecture with the capabilities to explore the local environment, plan and schedule events based on its knowledge, and request desired actions from the resources in the system is presented and tested.     

A knowledge-based tool for designing cyber physical production systems

Changing production systems and product requirements can trace their origin in volatile customer behaviour and evolving product requirements. This dynamic nature of customer requirements has been described as a constantly moving target, thus presenting a significant challenge for several aspects of product development. To deal with this constant and sometimes unpredictable product evolution, cyber physical production systems (CPPS) that employ condition monitoring, self-awareness and reconfigurability principles, have to be designed and implemented. This research contributes a CPPS design approach that proactively provides the required CPPS design knowledge. This approach aims to minimise or avoids future consequences and disruptions on the CPPS. This knowledge needs to be provided at the right time whilst not being intrusive to the production system designer’s cognitive activity. To effectively deal with the complexity of the cyber physical production system design activity with a manual method would lead to a time consuming, and complex support tool which is hard to implement, and difficult to use. The CPPS design approach has therefore been implemented in a prototype digital factory tool. This paper describes in detail the system requirements and system architecture for this tool. In order to establish the effectiveness of the proposed approach for designing cyber physical production systems, the prototype digital factory tool has been evaluated with a case study and a number of semi-structured interviews with both industrial and scientific stakeholders. The encouraging results obtained from this research evaluation have shown that such an approach for supporting the CPPS design activity makes stakeholders aware of their decision consequences and is useful in practice. This result can lead the way for the development and integration of such knowledge-based decision-making approaches within state-of-the-art digital factory and Computer Aided Engineering Design (CAED) tools.     

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.     

Semi-automated architectural abstraction specifications for supporting software evolution

In this paper we present an approach for supporting the semi-automated architectural abstraction of architectural models throughout the software life-cycle. It addresses the problem that the design and implementation of a software system often drift apart as software systems evolve, leading to architectural knowledge evaporation. Our approach provides concepts and tool support for the semi-automatic abstraction of architecture component and connector views from implemented systems and keeping the abstracted architecture models up-to-date during software evolution. In particular, we propose architecture abstraction concepts that are supported through a domain-specific language (DSL). Our main focus is on providing architectural abstraction specifications in the DSL that only need to be changed, if the architecture changes, but can tolerate non-architectural changes in the underlying source code. Once the software architect has defined an architectural abstraction in the DSL, we can automatically generate architectural component views from the source code using model-driven development (MDD) techniques and check whether architectural design constraints are fulfilled by these models. Our approach supports the automatic generation of traceability links between source code elements and architectural abstractions using MDD techniques to enable software architects to easily link between components and the source code elements that realize them. It enables software architects to compare different versions of the generated architectural component view with each other. We evaluate our research results by studying the evolution of architectural abstractions in different consecutive versions of five open source systems and by analyzing the performance of our approach in these cases.     

Design and Simulative Evaluation of Architectural Physical Environment with Ecotect

1 Introduction Design and pre-estimate of architectural physical environment engineering is one of important research context in architectural engineering. Nowadays, living environment has been the focus as the government promotes sustainable development vigorously. And the quality of human’s living environment is closely linked with architectural physical environment especially under the situation of energy shortage. Architecture is the main reason of energy consumption and the waste is also…     

Towards an Integrated View on Architecture and its Evolution

Information about the evolution of a software architecture can be found in the source basis of a project and in the release history data such as modification and problem reports. Existing approaches deal with these two data sources separately and do not exploit the integration of their analyses. In this paper, we present an architecture analysis approach that provides an integration of both kinds of evolution data. The analysis applies fact extraction and generates specific directed attributed graphs; nodes represent source code entities and edges represent relationships such as accesses, includes, inherits, invokes, and coupling between certain architectural elements. The integration of data is then performed on a meta-model level to enable the generation of architectural views using binary relational algebra. These integrated architectural views show intended and unintended couplings between architectural elements, hence pointing software engineers to locations in the system that may be critical for on-going and future maintenance activities. We demonstrate our analysis approach using a large open source software system.     

An object-oriented model for FMS control

The flexible manufacturing system (FMS) is a distributed network of heterogeneous programmable manufacturing machinery, such as assembly lines and numerically controlled machines. Despite these interconnected, programmable hardware elements, the success of building a truly flexible manufacturing system has been limited so far, owing to the lack of flexibility in its control software layer. In integrating heterogeneous machinery, many existing FMS control software systems depend structurally on specific machinery and job-scheduling strategies, and thus it is difficult to incorporate new developments in FMS organization and operational requirements. In searching for an open architecture for the FMS control software system, this paper presents an object-oriented FMS data model. Among others, it represents each physical cluster of related machinery (called a flexible manufacturing cell) as an object. To facilitate the integration of heterogeneous physical cells, such cell objects share a common protocol of interacting with the main control process through inheritance from the abstract cell class. Other related physical and abstract entities in FMS are also modelled as objects, with their similarity and difference captured in inheritance hierarchies. To verify the proposed approach experimentally, a prototype FMS control software system named FREE (FMS Runtime Executive Environment) has been implemented on top of a commercial object-oriented database system.     

An approach to regulating machine sharing in reconfigurable back-end semiconductor manufacturing

By complying with the operational philosophy of virtual production lines, a back-end semiconductor manufacturing system can be controlled and managed with better reconfigurability. However, due to the absence of a fully-integrated information system and the gaining popularity of distributed computing, machine reconfiguration decisions are made by machine controllers on the shop floor where heterarchical control architecture is typically used. This research investigates how non-cooperative game theory could be applied for facilitating the decision process reconfiguration decision-making at the machine controller level as machines are competed by multiple jobs streams. This paper presents how material flow traffic can be better regulated in a reconfigurable manufacturing environment. A study using an industrial pilot system is discussed to demonstrate the applicability of the proposed approach, in which heuristics are used to determine the game specification.     

Architecture for embedded open software ecosystems

Software is prevalent in embedded products and may be critical for the success of the products, but manufacturers may view software as a necessary evil rather than as a key strategic opportunity and business differentiator. One of the reasons for this can be extensive supplier and subcontractor relationships and the cost, effort or unpredictability of the deliverables from the subcontractors are experienced as a major problem.The paper proposes open software ecosystem as an alternative approach to develop software for embedded systems, and elaborates on the necessary quality attributes of an embedded platform underlying such an ecosystem. The paper then defines a reference architecture consisting of 17 key decisions together with four architectural patterns, and provides the rationale why they are essential for an open software ecosystem platform for embedded systems in general and automotive systems in particular.The reference architecture is validated through a prototypical platform implementation in an industrial setting, providing a deeper understanding of how the architecture could be realised in the automotive domain.Four potential existing platforms, all targeted at the embedded domain (Android, OKL4, AUTOSAR and Robocop), are evaluated against the identified quality attributes to see how they could serve as a basis for an open software ecosystem platform with the conclusion that while none of them is a perfect fit they all have fundamental mechanisms necessary for an open software ecosystem approach.