Real-time vision-based multiple object tracking of a production process: Industrial digital twin case study

Abstract

The adoption of Industry 4.0 technologies within the manufacturing and process industries is widely accepted to have benefits for production cycles, increase system flexibility and give production managers more options on the production line through reconfigurable systems. A key enabler in Industry 4.0 technology is the rise in Cyber-Physical Systems (CPS) and Digital Twins (DTs). Both technologies connect the physical to the cyber world in order to generate smart manufacturing capabilities. State of the art research accurately describes the frameworks, challenges and advantages surrounding these technologies but fails to deliver on testbeds and case studies that can be used for development and validation. This research demonstrates a novel proof of concept Industry 4.0 production system which lays the foundations for future research in DT technologies, process optimisation and manufacturing data analytics. Using a connected system of commercial off-the-shelf cameras to retrofit a standard programmable logic controlled production process, a digital simulation is updated in real time to create the DT. The system can identify and accurately track the product through the production cycle whilst updating the DT in real-time. The implemented system is a lightweight, low cost, customable and scalable design solution which provides a testbed for practical Industry 4.0 research both for academic and industrial research purposes.

Retrofitting-Based Development of Brownfield Industry 4.0 and Industry 5.0 Solutions

“…Cameras, Steel Mill [20], Phone assembly experimental plant [110] Light Detection and Ranging (Li-DAR) scanning, Material processing [130] Computer vision programmed in LabView platform, Experimental plant [21]…”

“…The LoRaWAN connectivity is integrated into a PLC in [111], which enhances the field device connection. To retrofit an old system, new PLCs can be deployed to perform logic control on system modules such as conveyors [110]. Generally speaking, to integrate legacy PLCs with limited connectivity into an IoT system, several components such as communication protocols, programming language, and execution environment should be taken.…”

“…The chosen communication protocol for the system. OPC Unified Architecture (OPC UA) Textile [15], [71], [97], Phone assembly experimental plant [110], Food processing [51], [73], FMS system [12], [16], [65], Sand core [68], Metal cutting [93], [118],…”

“…Digital twin (DT) is one of the critical players in I4.0 development in terms of plant-wide optimization [129]. The development of DT is desired in many retrofitting projects, as the goal of full-scope digitization is to be the foundation for other managerial activities, and resource planning [110]. DT can be used as the tracking simulator and integrated with the existing legacy control system of brownfield manufacturing facilities [130].…”

“…The DT can be constructed with the aided software and relevant algorithm Siemens Tecnomatix Process Simulate, Experimental plant [21], [110],…”