Automation Pyramid as Constructor for a Complete Digital Twin, Case Study: A Didactic Manufacturing System

Abstract

Nowadays, the concept of Industry 4.0 aims to improve factories’ competitiveness. Usually, manufacturing production is guided by standards to segment and distribute its processes and implementations. However, industry 4.0 requires innovative proposals for disruptive technologies that engage the entire production process in factories, not just a partial improvement. One of these disruptive technologies is the Digital Twin (DT). This advanced virtual model runs in real-time and can predict, detect, and classify normal and abnormal operating conditions in factory processes. The Automation Pyramid (AP) is a conceptual element that enables the efficient distribution and connection of different actuators in enterprises, from the shop floor to the decision-making levels. When a DT is deployed into a manufacturing system, generally, the DT focuses on the low-level that is named field level, which includes the physical devices such as controllers, sensors, and so on. Thus, the partial automation based on the DT is accomplished, and the information between all manufacturing stages could be decremented. Hence, to achieve a complete improvement of the manufacturing system, all the automation pyramid levels must be included in the DT concept. An artificial intelligent management system could create an interconnection between them that can manage the information. As a result, this paper proposed a complete DT structure covering all automation pyramid stages using Artificial Intelligence (AI) to model each stage of the AP based on the Digital Twin concept. This work proposes a virtual model for each level of the traditional AP and the interactions among them to flow and control information efficiently. Therefore, the proposed model is a valuable tool in improving all levels of an industrial process. In addition, It is presented a case study where the DT concept for modular workstations underpins the development of technologies within the framework of the Automation Pyramid model is implemented into a didactic manufacturing system.

Hybrid Virtual Commissioning of a Robotic Manipulator with Machine Vision Using a Single Controller

“…In the literature, one can find many definitions of a DT; however, there is none that is recognized both in academia and across industry sectors [2]. At the same time, there are many approaches to the creation of a DT, see, e.g., [3][4][5][6]. In short, according to Schluse et al [7], DT can be understood as a representation of a real object or subobject with its data, functions and means to communicate in a digital environment.…”

Lean Manufacturing: Mapeamento de fluxo e cadeia de valor de uma indústria de produtos apícolas

“…A Figura 1 ilustra a representação dos níveis definidos pela ISA-95. O padrão internacional ISA-95 oferece um modelo de desenvolvimento e integração de sistemas empresariais e de controle em uma perspectiva de especificação por camadas, estruturando elementos como: nível 0 -sensores; nível 1 -controladores lógicos programáveis (Programmable Logic Controller -PLC); nível 2 -sistemas de supervisão e aquisição de dados (Supervisory Control and Data Acquisition -SCADA) e interface homem-máquina (Human-Machine Interface -HMI); nível 3 -sistemas de operações de manufatura com MES; nível 4 -sistemas corporativos via ERP (MARTINEZ et al, 2021). É função do MES entregar informações reais e atuais, possibilitando a otimização da produção, de atividades desde o carregamento de uma ordem de produção até o produto acabado (CHEN; NOPHUT; VOIGT, 2020).…”

Knowledge Integration in Smart Factories

“…It is important to define the scope and purpose as the DT may address various aspects next to simulation [46]. Martinez et al (2021) recently conducted research where they reflected that DTs can be implemented on all levels of the classical automation pyramid while applying AI concepts, thus also indicating that a DT implementation is not only focused on one level but is a holistic approach [47]. Harrison, Vera and Ahmad (2021) also see an evolution of the automation pyramid due to "data-driven manufacturing capabilities" [43].…”