Digital twin-based real-time energy optimization method for production line considering fault disturbances

Xia, Tangbin; Sun, He; Ding, Yutong; Han, Dongyang; Qin, Wei; Seidelmann, Joachim; Xi, Lifeng

doi:10.1007/s10845-023-02219-9

Cited by 6 publications

(4 citation statements)

References 34 publications

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“…Planning and design, virtual commissioning [19][20][21][22][23][24] Optimization of the layout and balance [22,25] Virtual commissioning [6,[26][27][28] Reconfiguration of production lines Production scheduling and process control [29][30][31][32] Scheduling decisions [8,[33][34][35][36][37][38][39][40][41] Optimization of processing parameters [2,[42][43][44][45][46][47][48][49] Route planning and visualization [7,50] Reducing energy consumption and the scrap rate Prediction, maintenance, and fault diagnosis [31,51,52] Fault diagnosis [46,53] Optimized maintenance planning [54] Predicting production plans [48,[55][56][57] Predicting energy consumption or operational performance…”

Section: Ref Commentmentioning

confidence: 99%

“…Guo [24] proposed a multi-objective optimization including optimization of the layout, processing capability, logistics, and test equipment. Another study [7,8] used an improved genetic algorithm with the goal of minimizing the consumption of time and energy. Other research [39] used a real-coded genetic algorithm to improve the geometrical quality of each assembly.…”

Section: Iterative Optimization Algorithmsmentioning

confidence: 99%

“…Ren [6] proposed a framework for the reconstruction of production lines and intelligent monitoring of the manual assembly of customized products based on DT to solved the problems of easy misassembly and low efficiency. Xia [7] proposed a DT-based real-time energy optimization method for reducing energy consumption in production lines based on DT technologies. To solve the problematic control of production speed and optimization of the processing sequence in the welding process, Liu [8] developed a capacity evaluation and scheduling optimization system for ship components.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Digital Twins for Discrete Manufacturing Lines: A Review

Feng,

Wan

2024

BDCC

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Along with the development of new-generation information technology, digital twins (DTs) have become the most promising enabling technology for smart manufacturing. This article presents a statistical analysis of the literature related to the applications of DTs for discrete manufacturing lines, researches their development status in the areas of the design and improvement of manufacturing lines, the scheduling and control of manufacturing line, and predicting faults in critical equipment. The deployment frameworks of DTs in different applications are summarized. In addition, this article discusses the three key technologies of high-fidelity modeling, real-time information interaction methods, and iterative optimization algorithms. The current issues, such as fine-grained sculpting of twin models, the adaptivity of the models, delay issues, and the development of efficient modeling tools are raised. This study provides a reference for the design, modification, and optimization of discrete manufacturing lines.

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Section: Ref Commentmentioning

confidence: 99%

Section: Iterative Optimization Algorithmsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Digital Twins for Discrete Manufacturing Lines: A Review

Feng,

Wan

2024

BDCC

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“…Regarding the issue of non-real-time optimization of workshop energy consumption, Xia et al proposed a real-time optimization method for workshop energy consumption based on digital twin technology. By establishing a workshop digital twin model and combining the energy consumption characteristics, unit production time, production state, and behaviors of the equipment, a real-time energy consumption optimization considering fault interference was developed and validated in a shell production line [ 21 ]. On the basis of a digital twin-enabled energy-saving platform, Zhang et al proposed a stochastic dynamics model via max-plus algebra to characterize the spatio-temporal nature of state transition.…”

Section: Literature Reviewmentioning

confidence: 99%

Construction and Application of Energy Footprint Model for Digital Twin Workshop Oriented to Low-Carbon Operation

Zhang,

Zhuang,

Tian

et al. 2024

Sensors

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To address the difficulty of accurately characterizing the fluctuations in equipment energy consumption and the dynamic evolution of whole energy consumption in low-carbon workshops, a low-carbon-operation-oriented construction method of the energy footprint model (EFM) for a digital twin workshop (DTW) is proposed. With a focus on considering the fluctuations in equipment energy consumption and the correlation between multiple pieces of equipment at the workshop production process level (CBMEatWPPL), the EFM of a DTW is obtained to characterize the dynamic evolution of whole energy consumption in the workshop. Taking a production unit as a case, on the one hand, an EFM of the production unit is constructed, which achieved the characterization and visualization of the fluctuations in equipment energy consumption and the dynamic evolution of whole energy consumption in the production unit; on the other hand, based on the EFM, an objective function of workshop energy consumption is established, which is combined with the tool life, robot motion stability, and production time to formulate a multi-objective optimization function. The bee colony algorithm is adopted to solve the multi-objective optimization function, achieving collaborative optimization of cross-equipment process parameters and effectively reducing energy consumption in the production unit. The effectiveness of the proposed method and constructed EFM is demonstrated from the above two aspects.

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