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]...
[...]
...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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Journal Article•DOI•

An Access Control Model for Resource Sharing Based on the Role-Based Access Control Intended for Multi-Domain Manufacturing Internet of Things

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Qiang Liu¹, Hao Zhang¹, Jiafu Wan², Xin Chen¹•Institutions (2)

Guangdong University of Technology¹, South China University of Technology²

19 Apr 2017-IEEE Access

TL;DR: The proposed access control model provides a quick and efficient authorization decision support for administrators in collaborative domain and ensures a secure access in resource sharing in MIoT.

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Abstract: Manufacturing Internet of Things (MIoT) represents the manufacturing oriented to Internet of Things with two important characteristics, resource sharing and process collaboration. Access control in resource sharing is very important for MIoT operation safety. This paper presents an access control model for resource sharing based on the role-based access control intended for multidomain MIoT. In multidomain systems, in order to response on the assigning request for permission for the certain role from the certain user, an authority action sequence named the authorization route is employed to determine an appropriate authorization state. In this paper, the best authorization route with the least spread of permissions is defined as an optimal authorization route. We employed an intelligent planning theory to model the authorization route problem and to develop a solution algorithm called PGAO*, which can support external evaluation of both single-goal-role authorization routes and multi-goal-role authorization routes. In addition, some simple policies for solving the authorization route problem are presented. The proposed access control model provides a quick and efficient authorization decision support for administrators in collaborative domain and ensures a secure access in resource sharing in MIoT.

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62 citations

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

...time states of equipment [14], [15], work-in-process [16], materials [17], etc....
[...]

Journal Article•DOI•

Machine monitoring system based on MTConnect technology

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Ben Edrington, Bingyan Zhao, Adam Hansel, Masahiko Mori, Makoto Fujishima - Show less +1 more

01 Jan 2014-Procedia CIRP

TL;DR: In this paper, the authors introduce a web-based machine monitoring system that provides data collection, analysis, and machine event notification for MTConnect compatible machines, providing shop managers with the information needed to improve process efficiency on the shop floor, and increase overall equipment effectiveness (OEE).

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56 citations

Additional excerpts

...[18] B. Edrington, B. Y. Zhao, A. Hansel, M. Mori, and M. Fujishima, ‘‘Machine monitoring system based onMTConnect technology,’’ Procedia CIRP, vol. 22, pp. 92–97, Dec. 2014....
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...Meanwhile, standardized technologies and devices are studied to shield the heterogeneity of protocols and interfaces, such as MTConnect [18], middleware technology [19], coherent and semantic encapsulation for field data [20], [21]....
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Journal Article•DOI•

A novel facility layout planning and optimization methodology

[...]

S. Jiang¹, Andrew Y. C. Nee¹•Institutions (1)

National University of Singapore¹

01 Jan 2013-CIRP Annals

TL;DR: In this paper, a real-time on-site facility layout planning (FLP) system is presented where users can construct existing facilities as virtual primitive models, and a criterion and constraint definition mechanism is provided to define and customize the planning criteria and constraints to suit specific requirements of different FLP tasks.

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54 citations

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

...After that, layout optimization [28], production planning [29], [30] and fault diagnosis [31], etc....
[...]

Journal Article•DOI•

Energy Consumption Estimation for Machining Processes Based on Real-time Shop Floor Monitoring via Wireless Sensor Networks☆

[...]

Dimitris Mourtzis¹, Ekaterini Vlachou¹, Nikolaos Milas¹, George Dimitrakopoulos¹•Institutions (1)

University of Patras¹

01 Jan 2016-Procedia CIRP

TL;DR: In this article, a machine tool monitoring methodology that integrates sensory systems, a scheduling module, and human operators to perform real-time monitoring on the shop floor is presented, where the collected information is fused through an information fusion mechanism to extract meaningful results.

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53 citations

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

...time states of equipment [14], [15], work-in-process [16], materials [17], etc....
[...]

Journal Article•DOI•

Seamless Link-Level Redundancy to Improve Reliability of Industrial Wi-Fi Networks

[...]

Gianluca Cena¹, Stefano Scanzio¹, Adriano Valenzano¹•Institutions (1)

National Research Council¹

27 Jan 2016-IEEE Transactions on Industrial Informatics

TL;DR: A reference architecture is introduced, which describes how seamless link-level redundancy can be applied to Wi-Fi and includes two optimizations aimed at improving the quality of wireless communication by avoiding unnecessary replicated transmissions.

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Abstract: The adoption of wireless communications and, in particular, Wi-Fi, at the lowest level of the factory automation hierarchy has not increased as fast as expected so far, mainly because of serious issues concerning determinism. Actually, besides the random access scheme, disturbance and interference prevent reliable communication over the air and, as a matter of fact, make wireless networks unable to support distributed real-time control applications properly. Several papers recently appearing in literature suggest that diversity could be leveraged to overcome this limitation effectively. In this paper, a reference architecture is introduced, which describes how seamless link-level redundancy can be applied to Wi-Fi. The framework is general enough to serve as a basis for future protocol enhancements, and also includes two optimizations aimed at improving the quality of wireless communication by avoiding unnecessary replicated transmissions. Some relevant solutions have been analyzed by means of a thorough simulation campaign, in order to highlight their benefits when compared with conventional Wi-Fi. Results show that both packet losses and network latencies improve noticeably.

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53 citations