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Journal ArticleDOI

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

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.
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.
Citations
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Journal ArticleDOI
Qinglin Qi1, Fei Tao1Institutions (1)
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.
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.

461 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 ArticleDOI
Fei Tao1, He Zhang1, Ang Liu2, Andrew Y. C. Nee3Institutions (3)
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.
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.

442 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 ArticleDOI
Yuqian Lu1, Chao Liu2, Kevin I-Kai Wang1, Huiyue Huang1  +1 moreInstitutions (2)
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.
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.

283 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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Journal ArticleDOI
Cunbo Zhuang1, Jianhua Liu1, Xiong Hui1Institutions (1)
TL;DR: A framework of digital twin-based smart production management and control approach for complex product assembly shop-floors for cyber-physical systems (CPS) and how to apply the proposed approach to reality is proposed.
Abstract: Digital twin technology is considered as a key technology to realize cyber-physical systems (CPS) However, due to the complexity of building a digital equivalent in virtual space to its physical counterpart, very little progress has been achieved in digital twin application, especially in the complex product assembly shop-floor In this paper, we propose a framework of digital twin-based smart production management and control approach for complex product assembly shop-floors Four core techniques embodied in the framework are illustrated in detail as follows: (1) real-time acquisition, organization, and management of the physical assembly shop-floor data, (2) construction of the assembly shop-floor digital twin, (3) digital twin and big data-driven prediction of the assembly shop-floor, and (4) digital twin-based assembly shop-floor production management and control service To elaborate how to apply the proposed approach to reality, we present detailed implementation process of the proposed digital twin-based smart production management and control approach in a satellite assembly shop-floor scenario Meanwhile, the future work to completely fulfill digital twin-based smart production management and control concept for complex product assembly shop-floors are discussed

207 citations


Journal ArticleDOI
Fei Tao1, Qinglin Qi1, Lihui Wang2, Andrew Y. C. Nee3Institutions (3)
01 Aug 2019-Engineering
TL;DR: This paper reviews and analyzes CPS and DTs from multiple perspectives, including their origin, development, engineering practices, cyber–physical mapping, and core elements.
Abstract: State-of-the-art technologies such as the Internet of Things (IoT), cloud computing (CC), big data analytics (BDA), and artificial intelligence (AI) have greatly stimulated the development of smart manufacturing. An important prerequisite for smart manufacturing is cyber–physical integration, which is increasingly being embraced by manufacturers. As the preferred means of such integration, cyber–physical systems (CPS) and digital twins (DTs) have gained extensive attention from researchers and practitioners in industry. With feedback loops in which physical processes affect cyber parts and vice versa, CPS and DTs can endow manufacturing systems with greater efficiency, resilience, and intelligence. CPS and DTs share the same essential concepts of an intensive cyber–physical connection, real-time interaction, organization integration, and in-depth collaboration. However, CPS and DTs are not identical from many perspectives, including their origin, development, engineering practices, cyber–physical mapping, and core elements. In order to highlight the differences and correlation between them, this paper reviews and analyzes CPS and DTs from multiple perspectives.

200 citations


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

  • ...The first and most important step is to create high-fidelity virtual models to realistically reproduce the geometries, physical properties, behaviors, and rules of the physical world [22]....

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  • ...Recently, DTs have also been adopted in various industries for purposes including product design [20], production line design [21], DT shop floors [22], production process optimization [23], and prognosis and health management [24]....

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  • ...6, models integrating the geometry, structure, material properties, rules, process, and so forth [22] enable the digitization and visualization of the production system and process....

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References
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Journal ArticleDOI
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.
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.

806 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....

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  • ...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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Book ChapterDOI
Michael W. Grieves1, John Vickers2Institutions (2)
01 Jan 2017-
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.

584 citations


Journal ArticleDOI
Fei Tao1, Lin Zhang1, V C Venkatesh2, Y Luo1  +1 moreInstitutions (2)
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.
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.

479 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 ArticleDOI
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.
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.

394 citations


Journal ArticleDOI
Ray Y. Zhong1, Qingyun Dai2, Ting Qu1, G. J. Hu  +1 moreInstitutions (2)
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.

382 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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Performance
Metrics
No. of citations received by the Paper in previous years
YearCitations
20225
2021171
2020121
201976
201833