Digital Twin Shop-Floor: A New Shop-Floor Paradigm Towards Smart Manufacturing

doi:10.1109/ACCESS.2017.2756069

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Digital Twin Shop-Floor: A New Shop-Floor Paradigm Towards Smart Manufacturing

Journal Article•DOI•

Digital Twin Shop-Floor: A New Shop-Floor Paradigm Towards Smart Manufacturing

Fei Tao¹, Meng Zhang¹•Institutions (1)

Beihang University¹

26 Sep 2017-IEEE Access (IEEE)-Vol. 5, pp 20418-20427

TL;DR: A novel concept of digital twin shop-floor (DTS) based on digital twin is explored and its four key components are discussed, including physicalShop-floor, virtual shop- Floor, shop- floor service system, and shop-ground digital twin data.

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Abstract: With the developments and applications of the new information technologies, such as cloud computing, Internet of Things, big data, and artificial intelligence, a smart manufacturing era is coming. At the same time, various national manufacturing development strategies have been put forward, such as Industry 4.0 , Industrial Internet , manufacturing based on Cyber-Physical System , and Made in China 2025 . However, one of specific challenges to achieve smart manufacturing with these strategies is how to converge the manufacturing physical world and the virtual world, so as to realize a series of smart operations in the manufacturing process, including smart interconnection, smart interaction, smart control and management, etc. In this context, as a basic unit of manufacturing, shop-floor is required to reach the interaction and convergence between physical and virtual spaces, which is not only the imperative demand of smart manufacturing, but also the evolving trend of itself. Accordingly, a novel concept of digital twin shop-floor (DTS) based on digital twin is explored and its four key components are discussed, including physical shop-floor, virtual shop-floor, shop-floor service system, and shop-floor digital twin data. What is more, the operation mechanisms and implementing methods for DTS are studied and key technologies as well as challenges ahead are investigated, respectively.

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Journal Article•DOI•

Digital Twin in Industry: State-of-the-Art

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Fei Tao¹, He Zhang¹, Ang Liu², Andrew Y. C. Nee³•Institutions (3)

Beihang University¹, University of New South Wales², National University of Singapore³

01 Apr 2019-IEEE Transactions on Industrial Informatics

TL;DR: This paper thoroughly reviews the state-of-the-art of the DT research concerning the key components of DTs, the current development ofDTs, and the major DT applications in industry and outlines the current challenges and some possible directions for future work.

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Abstract: Digital twin (DT) is one of the most promising enabling technologies for realizing smart manufacturing and Industry 4.0. DTs are characterized by the seamless integration between the cyber and physical spaces. The importance of DTs is increasingly recognized by both academia and industry. It has been almost 15 years since the concept of the DT was initially proposed. To date, many DT applications have been successfully implemented in different industries, including product design, production, prognostics and health management, and some other fields. However, at present, no paper has focused on the review of DT applications in industry. In an effort to understand the development and application of DTs in industry, this paper thoroughly reviews the state-of-the-art of the DT research concerning the key components of DTs, the current development of DTs, and the major DT applications in industry. This paper also outlines the current challenges and some possible directions for future work.

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1,467 citations

Cites background from "Digital Twin Shop-Floor: A New Shop..."

...resents the physical entity; VE represents the virtual entity; Ss represents the services for both PE and VE; DD stands for the DT data; and CN means the connection of different parts [12], [74]....
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...As for the application of DTs in the PHM, different aspects of aircraft were the primary research subjects, such as wings, structural life, and touch-down wear [12], [41], [47]....
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...how DTs could serve intelligent manufacturing [12]....
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...On the one hand, almost every paper [3], [4], [6], [9]–[12], [26]–[28], [31]–[53] acknowledged the importance of DT modeling....
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...proposed that a complete DT should include five dimensions: physical part, virtual part, connection, data, and service [12]....
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Journal Article•DOI•

Digital Twin and Big Data Towards Smart Manufacturing and Industry 4.0: 360 Degree Comparison

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Qinglin Qi¹, Fei Tao¹•Institutions (1)

Beihang University¹

15 Jan 2018-IEEE Access

TL;DR: The similarities and differences between big data and digital twin are compared from the general and data perspectives and how they can be integrated to promote smart manufacturing are discussed.

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Abstract: With the advances in new-generation information technologies, especially big data and digital twin, smart manufacturing is becoming the focus of global manufacturing transformation and upgrading. Intelligence comes from data. Integrated analysis for the manufacturing big data is beneficial to all aspects of manufacturing. Besides, the digital twin paves a way for the cyber-physical integration of manufacturing, which is an important bottleneck to achieve smart manufacturing. In this paper, the big data and digital twin in manufacturing are reviewed, including their concept as well as their applications in product design, production planning, manufacturing, and predictive maintenance. On this basis, the similarities and differences between big data and digital twin are compared from the general and data perspectives. Since the big data and digital twin can be complementary, how they can be integrated to promote smart manufacturing are discussed.

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856 citations

Cites background from "Digital Twin Shop-Floor: A New Shop..."

...physical world, have been being strengthened [28]....
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...Digital twin reflects two-way dynamic mapping of physical objects and virtual models [28]....
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Journal Article•DOI•

Characterising the Digital Twin: A systematic literature review

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David Edward Jones¹, Chris Snider¹, Aydin Nassehi¹, Jason Yon¹, Ben Hicks¹ - Show less +1 more•Institutions (1)

University of Bristol¹

09 Mar 2020-Cirp Journal of Manufacturing Science and Technology

TL;DR: A characterisation of the Digital Twin is provided, identification of gaps in knowledge, and required areas of future research are identified: Perceived Benefits; Digital Twin across the Product Life-Cycle; Use-Cases; Technical Implementations; Levels of Fidelity; Data Ownership; and Integration between Virtual Entities; each of which are required to realise the Digital twin.

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Abstract: While there has been a recent growth of interest in the Digital Twin, a variety of definitions employed across industry and academia remain. There is a need to consolidate research such to maintain a common understanding of the topic and ensure future research efforts are to be based on solid foundations. Through a systematic literature review and a thematic analysis of 92 Digital Twin publications from the last ten years, this paper provides a characterisation of the Digital Twin, identification of gaps in knowledge, and required areas of future research. In characterising the Digital Twin, the state of the concept, key terminology, and associated processes are identified, discussed, and consolidated to produce 13 characteristics (Physical Entity/Twin; Virtual Entity/Twin; Physical Environment; Virtual Environment; State; Realisation; Metrology; Twinning; Twinning Rate; Physical-to-Virtual Connection/Twinning; Virtual-to-Physical Connection/Twinning; Physical Processes; and Virtual Processes) and a complete framework of the Digital Twin and its process of operation. Following this characterisation, seven knowledge gaps and topics for future research focus are identified: Perceived Benefits; Digital Twin across the Product Life-Cycle; Use-Cases; Technical Implementations; Levels of Fidelity; Data Ownership; and Integration between Virtual Entities; each of which are required to realise the Digital Twin.

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775 citations

Cites methods from "Digital Twin Shop-Floor: A New Shop..."

...5 Fidelity [33] [80] [108] [24] [85] [8] [56] [88] [68] [112] [99] [78] [32] [111] [36] [7] [71] [63] [61] [73] [20] [67] [6] [4] [48] [55] [95] [16] [92] [98] [87] [9] [66] [110] [18] [89] [12]...
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...16 Technical Implementations [16] [98] [87] [51] [12] [57] [77] [100] [112] [105] [11] [109] [22] [17] [16] [16] [94] [112] [111] [107] [112] [111] [107] [106] [112] [110] [5] [57] [75] [104] [71] [2] [27] [6] [55] [16] [87] [46] [80] [8] [100] [88] [84] [112] [46] [80]...
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...4 Virtual Environment [33] [42] [103] [80] [77] [94] [53] [85] [8] [100] [15] [97] [56] [88] [68] [84] [112] [104] [99] [78] [1] [111] [46] [106] [30] [7] [63] [76] [54] [14] [109] [21] [73] [20] [67] [27] [90] [6] [17] [91] [48] [55] [49] [16] [92] [98] [62] [87] [110] [89] [5] [51] [57]...
[...]
...1 Physical Entity [33] [103] [80] [72] [77] [28] [94] [53] [108] [24] [85] [74] [8] [15] [64] [56] [88] [75] [68] [84] [112] [104] [37] [99] [78] [1] [105] [32] [111] [46] [36] [52] [11] [106] [30] [7] [71] [63] [29] [76] [54] [14] [109] [21] [61] [73] [2] [40] [67] [86] [27] [90] [58] [35] [22] [70] [6] [17] [91] [4] [48] [55] [49] [95] [16] [92] [98] [62] [87] [107] [39] [3] [9] [66] [110] [18] [89] [5] [51] [12] [57] [101]...
[...]
...2 Virtual Entity [33] [103] [80] [72] [77] [108] [85] [74] [8] [15] [64] [23] [56] [88] [75] [68] [84] [47] [112] [104] [37] [99] [78] [1] [105] [32] [111] [46] [36] [52] [11] [106] [30] [71] [63] [29] [76] [54] [14] [109] [21] [61] [73] [20] [2] [67] [27] [58] [35] [22] [70] [6] [17] [91] [4] [48] [55] [49] [95] [16] [92] [98] [62] [87] [107] [9] [110] [18] [89] [5] [51] [12] [57]...
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Journal Article•DOI•

Digital Twin: Enabling Technologies, Challenges and Open Research

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Aidan Fuller¹, Zhong Fan¹, Charles R. Day¹, Chris Barlow•Institutions (1)

Keele University¹

28 May 2020-IEEE Access

TL;DR: Digital twins as discussed by the authors is an emerging concept that has become the centre of attention for industry and, in recent years, academia and a review of publications relating to Digital Twins is performed, producing a categorical review of recent papers.

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Abstract: Digital Twin technology is an emerging concept that has become the centre of attention for industry and, in more recent years, academia. The advancements in industry 4.0 concepts have facilitated its growth, particularly in the manufacturing industry. The Digital Twin is defined extensively but is best described as the effortless integration of data between a physical and virtual machine in either direction. The challenges, applications, and enabling technologies for Artificial Intelligence, Internet of Things (IoT) and Digital Twins are presented. A review of publications relating to Digital Twins is performed, producing a categorical review of recent papers. The review has categorised them by research areas: manufacturing, healthcare and smart cities, discussing a range of papers that reflect these areas and the current state of research. The paper provides an assessment of the enabling technologies, challenges and open research for Digital Twins.

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739 citations

Journal Article•DOI•

Digital Twin-driven smart manufacturing: Connotation, reference model, applications and research issues

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Yuqian Lu¹, Chao Liu², Kevin I-Kai Wang¹, Huiyue Huang¹, Xun Xu¹ - Show less +1 more•Institutions (2)

University of Auckland¹, Cardiff University²

01 Feb 2020-Robotics and Computer-integrated Manufacturing

TL;DR: The definition and state-of-the-art development outcomes of Digital Twin are summarized, and outstanding research issues of developing Digital Twins for smart manufacturing are identified.

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Abstract: This paper reviews the recent development of Digital Twin technologies in manufacturing systems and processes, to analyze the connotation, application scenarios, and research issues of Digital Twin-driven smart manufacturing in the context of Industry 4.0. To understand Digital Twin and its future potential in manufacturing, we summarized the definition and state-of-the-art development outcomes of Digital Twin. Existing technologies for developing a Digital Twin for smart manufacturing are reviewed under a Digital Twin reference model to systematize the development methodology for Digital Twin. Representative applications are reviewed with a focus on the alignment with the proposed reference model. Outstanding research issues of developing Digital Twins for smart manufacturing are identified at the end of the paper.

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649 citations

Cites background or methods from "Digital Twin Shop-Floor: A New Shop..."

...[8] Shop floor - Digital Twin of shop floor to support smart operations in the manufacturing process...
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...Tao and Zhang believed that Digital Twin is a method of achieving the convergence between physical and virtual spaces [8]....
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References

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Open Access

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Book Chapter•DOI•

Digital Twin: Mitigating Unpredictable, Undesirable Emergent Behavior in Complex Systems

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Michael W. Grieves¹, John Vickers²•Institutions (2)

Florida Institute of Technology¹, Marshall Space Flight Center²

01 Jan 2017

TL;DR: Digital twins as discussed by the authors link the physical system with its virtual equivalent to mitigate the problematic issues due to human interaction in the process of creation, production, operations, and disposal of a system.

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Abstract: Systems do not simply pop into existence. They progress through lifecycle phases of creation, production, operations, and disposal. The issues leading to undesirable and unpredicted emergent behavior are set in place during the phases of creation and production and realized during the operational phase, with many of those problematic issues due to human interaction. We propose that the idea of the Digital Twin, which links the physical system with its virtual equivalent can mitigate these problematic issues. We describe the Digital Twin concept and its development, show how it applies across the product lifecycle in defining and understanding system behavior, and define tests to evaluate how we are progressing. We discuss how the Digital Twin relates to Systems Engineering and how it can address the human interactions that lead to “normal accidents.” We address both Digital Twin obstacles and opportunities, such as system replication and front running. We finish with NASA’s current work with the Digital Twin.

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1,031 citations

Journal Article•DOI•

Cyber-physical production systems: Roots, expectations and R&D challenges

[...]

László Monostori¹, László Monostori²•Institutions (2)

Hungarian Academy of Sciences¹, Budapest University of Technology and Economics²

01 Jan 2014-Procedia CIRP

TL;DR: There are significant roots generally and particularly in the CIRP community -which point towards CPPSs, and Expectations and the related new R&D challenges will be outlined.

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Abstract: One of the most significant directions in the development of computer science and information and communication technologies is represented by Cyber-Physical Systems (CPSs) which are systems of collaborating computational entities which are in intensive connection with the surrounding physical world and its on-going processes, providing and using, at the same time, data-Accessing and data-processing services available on the internet. Cyber-Physical Production Systems (CPPSs), relying on the newest and foreseeable further developments of computer science, information and communication technologies on the one hand, and of manufacturing science and technology, on the other, may lead to the 4th Industrial Revolution, frequently noted as Industry 4.0. The key-note will underline that there are significant roots generally -And particularly in the CIRP community -which point towards CPPSs. Expectations and the related new R&D challenges will be outlined. © 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license.

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971 citations

"Digital Twin Shop-Floor: A New Shop..." refers background in this paper

...For example, Monostori [6] applies the concept of Cyber-Physical Production System (CPPS), which has the potential to achieve a more decentralized way of functioning and interacting....
[...]
...For example, Monostori [6] applies the concept of Cyber-Physical Production System (CPPS), which has the potential to achieve a more decentralized way...
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...[6] L. Monostori, ‘‘Cyber-physical production systems: Roots, expectations and R&D challenges,’’ Procedia CIRP, vol. 17, pp. 9–13, Jan. 2014....
[...]

Journal Article•DOI•

Reengineering Aircraft Structural Life Prediction Using a Digital Twin

[...]

Eric J. Tuegel, Anthony R. Ingraffea, Thomas Eason, S. Michael Spottswood

23 Oct 2011-International Journal of Aerospace Engineering

TL;DR: A conceptual model of how the Digital Twin can be used for predicting the life of aircraft structure and assuring its structural integrity is presented and the technical challenges to developing and deploying a Digital Twin are discussed.

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Abstract: Reengineering of the aircraft structural life prediction process to fully exploit advances in very high performance digital computing is proposed. The proposed process utilizes an ultrahigh fidelity model of individual aircraft by tail number, a Digital Twin, to integrate computation of structural deflections and temperatures in response to flight conditions, with resulting local damage and material state evolution. A conceptual model of how the Digital Twin can be used for predicting the life of aircraft structure and assuring its structural integrity is presented. The technical challenges to developing and deploying a Digital Twin are discussed in detail.

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681 citations

Journal Article•DOI•

Cloud manufacturing: a computing and service-oriented manufacturing model:

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Fei Tao¹, Lin Zhang¹, V C Venkatesh², Y Luo¹, Ying Cheng¹ - Show less +1 more•Institutions (2)

Beihang University¹, University of Nevada, Las Vegas²

22 Aug 2011

TL;DR: The concept, architecture, core enabling technologies, and typical characteristics of CMfg are discussed and investigated, as well as the differences and relationship between cloud computing and CMfg.

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Abstract: Combining the emerged advanced technologies (such as cloud computing, ‘internet of thing’, virtualization, and service-oriented technologies, advanced computing technologies) with existing advanced manufacturing models and enterprise ‘informationization’ technologies, a new computing- and service-oriented manufacturing model, called cloud manufacturing (CMfg), is proposed. The concept, architecture, core enabling technologies, and typical characteristics of CMfg are discussed and investigated, as well as the differences and relationship between cloud computing and CMfg. Four typical CMfg service platforms, i.e. public, private, community, and hybrid CMfg service platforms, are introduced. The key advantages and challenges for implementing CMfg are analysed, as well as the key technologies and main research findings.

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530 citations

"Digital Twin Shop-Floor: A New Shop..." refers background in this paper

...0, Industrial Internet, Made in China 2025, service oriented manufacturing [1], [2] and cloud manufacturing [3], [4]) to prepare for the next...
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Journal Article•DOI•

RFID-enabled real-time manufacturing execution system for mass-customization production

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Ray Y. Zhong¹, Qingyun Dai², Ting Qu¹, G. J. Hu, George Q. Huang¹ - Show less +1 more•Institutions (2)

University of Hong Kong¹, Guangdong University of Technology²

01 Apr 2013-Robotics and Computer-integrated Manufacturing

TL;DR: In this article, an RFID-enabled real-time manufacturing execution system (RT-MES) is proposed to track and trace manufacturing objects and collect realtime production data.

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Abstract: Mass-customization production (MCP) companies must fight with shop-floor uncertainty and complexity caused by wide variety of product components. The research is motivated by a typical MCP company that has experienced inefficient scheduling due to paper-based identification and manual data collection. This paper presents an RFID-enabled real-time manufacturing execution system (RT-MES). RFID devices are deployed systematically on the shop-floor to track and trace manufacturing objects and collect real-time production data. Disturbances are identified and controlled within RT-MES. Planning and scheduling decisions are more practically and precisely made and executed. Online facilities are provided to visualize and manage real-time dynamics of shop-floor WIP (work-in-progress) items. A case study is reported in a collaborating company which manufactures large-scale and heavy-duty machineries. The efficiency and effectiveness of the proposed RT-MES are evaluated with real-life industrial data for shop-floor production management in terms of workers, machines and materials.

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424 citations

"Digital Twin Shop-Floor: A New Shop..." refers background in this paper

...build an RFID-enabled real-time manufacturing execution system, which provides more practical planning and scheduling decisions for shop-floor [25]....
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