A virtual commissioning based methodology to integrate digital twins into manufacturing systems

Abstract

Digital Twin (DT) is considered a key approach to enhance the system reactivity to uncertain events due to its ability to getting data from the field and triggering actions on the physical asset. Given the modern technological and rapidly changing work environment, it is likely that in the next years companies will need to retrofit their manufacturing systems by integrating DTs. In this context, it is fundamental to define the necessary steps for the development of DTs and for their integration into manufacturing systems through a DT architecture. In response to this issue, a methodology based on Virtual Commissioning is proposed. A stepwise approach is illustrated in which the DT is designed, integrated and verified using a virtual environment. The methodology is validated through the integration of a DT into a flow shop for the implementation of a scheduling reactive to machine breakdown. By following the steps of the proposed methodology, a DT architecture able to improve the makespan of the studied flow shop is developed, suggesting the potential applicability of the approach to industrial manufacturing systems.

A Digital Twin Architecture to Optimize Productivity within Controlled Environment Agriculture

“…Barbieri et al [31] proposed a methodology based on virtual commissioning-VCbased methodology-to retrofit manufacturing systems with DTs. The methodology consists of a stepwise approach in which the DT architecture is designed, integrated (to the retrofitted manufacturing system), and verified using a virtual environment before its implementation.…”

“…Methodology utilized for the development of the DT architecture for CEA systems. The representation has been adopted from[31].…”

Developing Digital Observer of Angular Gaps in Rolling Stand Mechatronic System

“…An approach based on building virtual models of an object with a subsequent transfer of the debugged algorithm in the controller software is used to design mechatronic complexes of industrial units. This principle is also applied in virtual commissioning [47][48][49][50], diagnosing, and forecasting the technical condition of equipment [51]. The blocks' connection facilitates the resolution of the angular velocity signal integration provided two conditions are met simultaneously: the static load torque is equal to the idling torque (open gap), and the drive braking has started.…”

“…An approach based on building virtual models of an object with a subsequent transfer of the debugged algorithm in the controller software is used to design mechatronic complexes of industrial units. This principle is also applied in virtual commissioning [47][48][49][50], diagnosing, and forecasting the technical condition of equipment [51].…”

Desarrollo De Un Gemelo Digital De Una Fábrica De Refrescos

“…El proceso de creación del gemelo digital se basó en recopilación de información, modelado de la planta, adaptación de sensores y actuadores al modelo, diseño del programa de control, comunicación entre modelo y planta, y por último la validación del proyecto, con el fin de lograr una puesta en marcha virtual o virtual commissioning (J. Brazina et al, 2020), (M. Grethler, J. Ovtcharova, & M. Marinov, 2020), (G. Barbieri et al, 2021).…”