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Journal ArticleDOI

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

Fei Tao1, Meng Zhang1
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
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.

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 ArticleDOI
Qinglin Qi1, Fei Tao1
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.

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 ArticleDOI
David Edward Jones1, Chris Snider1, Aydin Nassehi1, Jason Yon1, Ben Hicks1 
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.
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.

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]...

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  • ...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 ArticleDOI
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.
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.

739 citations

Journal ArticleDOI
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.

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
More filters
Journal ArticleDOI
TL;DR: A network architecture to seamlessly integrate CAN busses in intranets is described, finding a comprehensive solution that suits both inexpensive and very complex applications.

14 citations


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

  • ...nection of sensors, actuators and controllers and the related researches mainly cover the real-time communication mechanism [9], [10], protocol standardization [11], integration in intranet [12], [13], etc....

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Journal ArticleDOI
TL;DR: In this paper, an enhanced assembly planning process with valuable integrated VR assistance for a definite structured detection of planning failures is presented, where detailed holistic instructions for the workshop preparation and the VR use are given.

13 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....

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Proceedings ArticleDOI
22 Jul 2015
TL;DR: Two different approaches are presented and discussed in this paper - a single-master and a multi-master approach based on an extension of the standard EtherCAT state machine that shows how flexibility can increase by reconfiguration of the field-bus communication.
Abstract: The increasing demand for adaptive and flexible machines and plants raises the need for components and systems that can be dynamically reconfigured Therefore, production facilities are especially needed to allow for connecting or disconnecting machine modules at runtime to allow for flexible production orders and varying product types Many highly sophisticated approaches eg multi-agent systems and service-oriented architectures support reconfiguration at the application layer, but the communication link between the components' hardware has not yet been appropriately considered However, the deterministic behavior of a field-bus is required to perform such a system reconfiguration of plants without violating the maximum cycle time of control applications Considering these constraints, two different approaches are presented and discussed in this paper — a single-master and a multi-master approach Based on an extension of the standard EtherCAT state machine, it is shown how flexibility can increase by reconfiguration of the field-bus communication An evaluation of the reconfiguration time illustrates the impact to the control application

7 citations


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

  • ...nection of sensors, actuators and controllers and the related researches mainly cover the real-time communication mechanism [9], [10], protocol standardization [11], integration in intranet [12], [13], etc....

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Book ChapterDOI
12 Jan 2012

3 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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Book ChapterDOI
01 Jan 2015
TL;DR: In this chapter, CLPS-GA (A Case Library and Pareto Solution-based improved Genetic Algorithm) for addressing Energy-aware Cloud Service Scheduling (ECSS) in cloud manufacturing is introduced.
Abstract: In this chapter, CLPS-GA (A Case Library and Pareto Solution-based improved Genetic Algorithm) [Appl Soft Comput 11(3):3056–3065, 2004] for addressing Energy-aware Cloud Service Scheduling (ECSS) in cloud manufacturing is introduced.

3 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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