Modeling of Iot-Based Additive Manufacturing Machine’s Digital Twin for Error Detection

Abstract

Additive Manufacturing technology is one of the technologies that is changing the manufacturing industry. It has revealed some advantages over traditional manufacturing methods with this technology. With the advancement of information technologies, new approaches focusing on cost and improvement have begun to be adopted in the manufacturing industry. One such method is digital twin technology. A digital twin is frequently referred to as a digital replication of a physical system. Digital twins provide data and models to support the operation of design and manufacturing processes, as well as troubleshooting, diagnostics, and problem-solving. Various sensors are required to monitor the status of physical systems and transfer data to digital systems. Some of these Internet of Things-compatible sensors are already in production machines, but others can be added later. In the study, an Internet of Things-based system was proposed for the creation of digital twins using a virtual environment, and a digital twin simulation was created in order to bring the benefits of digitalization to production systems. The digital twin is modeled in the Matlab Simulink environment to perform binary classification to detect abnormal physical conditions that have the potential to disrupt the operation of the additive manufacturing machine and affect the quality of the manufacturing part. By generating a digital twin from real machine data, the proposed system will be able to detect errors.

Digital Twin Implementation in Additive Manufacturing: A Comprehensive Review

“…Additive manufacturing (AM) refers to the precise process of creating a tangible object in 3D based on digital data. This process involves adding successive layers of material, which distinguishes it from traditional methods that involve the subtraction of material [13,29]. Numerous AM techniques are available [30], each one characterized by the materials used and the method of layer deposition.…”

“…The notion of DT may be traced back to its initial introduction by the National Aeronautics and Space Administration (NASA), where it was employed to monitor satellite activity. This approach was also used to generate simulations of possible parameter changes [13]. NASA aimed to venture into space exploration using a DT, essentially a virtual model, simulating the physical satellite's behavior [60].…”

“…Additive manufacturing is recognized as an innovative and powerful technology of Industry 4.0 which provides greater flexibility and personalization in the development and manufacture of complex parts, enhances manufacturing competitiveness, and reduces production time and waste of materials [11][12][13]. The principles of Industry 4.0 are illustrated in additive manufacturing using real-time data and digital design files to regulate production processes.…”

MODELING AND SIMULATION OF INDUSTRIAL PROCESSES = Modelado y simulación de procesos industriales

“…These digital tools do more than just streamline operations; they allow for the simulation of industrial processes in virtual environments, providing a sandbox for innovation without the risks associated with physical trials. Tools like MATLAB, Simulink, and proprietary software specific to industries allow engineers to model scenarios and predict outcomes with a high degree of accuracy [23], [24].…”