Toward a Digital Twin for real-time geometry assurance in individualized production

doi:10.1016/J.CIRP.2017.04.038

Home
/
Papers
/
Toward a Digital Twin for real-time geometry assurance in individualized production

Journal Article•DOI•

Toward a Digital Twin for real-time geometry assurance in individualized production

Rikard Söderberg¹, Kristina Wärmefjord¹, Johan S. Carlson, Lars Lindkvist¹•Institutions (1)

Chalmers University of Technology¹

01 Jan 2017-Cirp Annals-manufacturing Technology (Elsevier)-Vol. 66, Iss: 1, pp 137-140

TL;DR: In this article, the authors highlight the functionality and data models necessary for real-time geometry assurance and how this concept allows moving from mass production to more individualized production, a concept referred to as a Digital Twin.

read less

Abstract: Simulations of products and production processes are extensively used in the engineering phase. To secure good geometrical quality in the final product, tolerances, locator positions, clamping strategies, welding sequence, etc. are optimized during design and pre-production. Faster optimization algorithms, increased computer power and amount of available data, can leverage the area of simulation toward real-time control and optimization of products and production systems - a concept often referred to as a Digital Twin. This paper specifies and highlights functionality and data models necessary for real-time geometry assurance and how this concept allows moving from mass production to more individualized production.

...read moreread less

Citations

PDF

Open Access

More filters

Journal Article•DOI•

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

[...]

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.

...read moreread less

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.

...read moreread less

1,467 citations

Additional excerpts

...discussed the DT application in real-time geometry assurance during the preproduction and production phases, based on a case study of the sheet metal assembly station [42]....
[...]

Journal Article•DOI•

Digital Twin in manufacturing: A categorical literature review and classification

[...]

Werner Kritzinger, Matthias Karner, Georg Traar, Jan Henjes, Wilfried Sihn - Show less +1 more

01 Jan 2018-IFAC-PapersOnLine

TL;DR: It is shown, that literature concerning the highest development stage, the DT, is scarce, whilst there is more literature about DM and DS.

...read moreread less

1,250 citations

Cites background from "Toward a Digital Twin for real-time..."

...Categorical literature review Reference Type Level of integration Focused area Technology Boschert, Rosen (2016) review DT product lifecycle simulation Bottani et al. (2017) case-study DT PPC simulation Brenner, Hummel (2017) definition DT PPC sensors Cai et al. (2017) concept DM maintenance simulation Frazzon et al. (2016) concept DM PPC discrete event simulation Friedemann Mattern (2010) review undefined manufacturing in general RFID Friedrich et al. (2014) concept DS maintenance - GE Power Digital Solutions (2016) study DM product lifecycle discrete event simulation, sensors Gyulai et al. (2016) concept DM layout planning Plant Simulation, TCP/IP, optimization Jain et al. (2001) concept DS layout planning simulation Kaylani, Atieh (2016) case-study DM PPC discrete event simulation Kuhlenkötter et al. (2017) concept DM product lifecycle - Kuhn (2017) review DT maintenance simulation Kumar et al. (2015) case-study DM PPC optimization Lee et al. (2013b) concept DS maintenance PHM, CPS Lee et al. (2013c) concept DS maintenance PHM, TCM, sensors Lindström et al. (2017) case-study DS maintenance PHM, sensors Mell, Grance (2011) case-study DS PPC visualization Müller et al. (2017) review DT manufacturing in general - Pawlaszczyk (2006) review DT manufacturing in general optimization Prager, David (2016) case-study DM product lifecycle simulation, SAP Reeves (2017) definition DT manufacturing in general simulation Rosen et al. (2015) case-study DM layout planning simulation, MBSE Salleh et al. (2017) case-study DM process design CPS, sensors Schleich et al. (2017) case-study undefined process design eRobotics, virtual testbed, CPS, MBSE Schluse, Rossmann (2016) case-study undefined PPC simulation, XML, CPS. Middleware Siemens PLM Software (2017) concept DS PPC simulation, OPC-UA Simons et al. (2017) concept DS PPC OPC-UA, Simulation;Physics, Simulation, SmartGlass, SAP, MES Singh et al. (2017) concept DS PPC MTConnect;MQTT;Database;NOSQL;Middleware Söderberg et al. (2017) concept DS PPC simulation Stark et al. (2017) review DS product lifecycle simulation Tao et al. (2017) concept DM PPC Semantic Web Terkaj, Urgo (2015) concept undefined PPC simulation, CPS Terkaj et al. (2015) concept DM process design simulation, Semantic Web, UML Theuer, Lass (2016) concept undefined PPC simulation, CPS, System Theory Uhlemann et al. (2017a) concept DT PPC Machine Vision, Simulation, optimization Uhlemann et al. (2017b) concept undefined PPC Value Stream Mapping, Material Flow Simulation, Learning Factory Um et al. (2017a) concept undefined PPC PLC, SOA, OPC-UA, RFID, Middleware, Platform, MQTT, ERP, MES, Visualization Um et al. (2017b) concept undefined PPC AutomationML, XML, CPS, PLC, OPC-UA, MQTT, MTConnect Vachálek et al. (2017) case-study DS PPC Plant Simulation, OPC-UA Weyer et al. (2016) concept DS PPC simulation, CPS, SOA Yang et al. (2016) concept DS PPC simulation, optimization Zhang et al. (2017) concept DS layout planning simulation DM = Digital Model, DS = Digital Shadow, DT = Digital Twin; IFAC INCOM 2018 Bergamo, Italy, June 11-13, 2018 1038 1020 Werner Kritzinger et al. / IFAC PapersOnLine 51-11 (2018) 1016–1022 Looking at the levels of integration, the majority of the publications are classified as Digital Shadows (35 percent) and Digital Models (28 percent)....
[...]
...…concept DS PPC OPC-UA, Simulation;Physics, Simulation, SmartGlass, SAP, MES Singh et al. (2017) concept DS PPC MTConnect;MQTT;Database;NOSQL;Middleware Söderberg et al. (2017) concept DS PPC simulation Stark et al. (2017) review DS product lifecycle simulation Tao et al. (2017) concept DM PPC…...
[...]

Journal Article•DOI•

Characterising the Digital Twin: A systematic literature review

[...]

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.

...read moreread less

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.

...read moreread less

775 citations

Journal Article•DOI•

Digital Twin: Values, Challenges and Enablers From a Modeling Perspective

[...]

Adil Rasheed¹, Omer San², Trond Kvamsdal³•Institutions (3)

Norwegian University of Science and Technology¹, Oklahoma State University–Stillwater², SINTEF³

28 Jan 2020-IEEE Access

TL;DR: This work reviews the recent status of methodologies and techniques related to the construction of digital twins mostly from a modeling perspective to provide a detailed coverage of the current challenges and enabling technologies along with recommendations and reflections for various stakeholders.

...read moreread less

Abstract: Digital twin can be defined as a virtual representation of a physical asset enabled through data and simulators for real-time prediction, optimization, monitoring, controlling, and improved decision making. Recent advances in computational pipelines, multiphysics solvers, artificial intelligence, big data cybernetics, data processing and management tools bring the promise of digital twins and their impact on society closer to reality. Digital twinning is now an important and emerging trend in many applications. Also referred to as a computational megamodel, device shadow, mirrored system, avatar or a synchronized virtual prototype, there can be no doubt that a digital twin plays a transformative role not only in how we design and operate cyber-physical intelligent systems, but also in how we advance the modularity of multi-disciplinary systems to tackle fundamental barriers not addressed by the current, evolutionary modeling practices. In this work, we review the recent status of methodologies and techniques related to the construction of digital twins mostly from a modeling perspective. Our aim is to provide a detailed coverage of the current challenges and enabling technologies along with recommendations and reflections for various stakeholders.

...read moreread less

660 citations

Cites methods from "Toward a Digital Twin for real-time..."

...A digital twin approach has been also highlighted in [48] as a real-time control and optimization tool towards individualized production systems....
[...]

Journal Article•DOI•

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

[...]

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.

...read moreread less

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.

...read moreread less

649 citations

Cites methods from "Toward a Digital Twin for real-time..."

...Using Digital Twin, together with intelligent algorithms, organizations can achieve data-driven operation monitoring and optimization [3], develop innovative product and services [4], and diversify value creation and business models [5]....
[...]

1
2
3
4
…
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78

Collapse

References

PDF

Open Access

More filters

Journal Article•DOI•

About The Importance of Autonomy and Digital Twins for the Future of Manufacturing

[...]

Roland Rosen¹, Georg von Wichert¹, George Lo², Kurt Dirk Bettenhausen²•Institutions (2)

Siemens¹, Princeton University²

01 Jan 2015-IFAC-PapersOnLine

TL;DR: In this paper, the authors discuss the importance of industrial manufacturing for economy and society, including the question about the future of labor and technical and technological questions that have to be taken care of as well.

...read moreread less

854 citations

Journal Article•DOI•

Recent advances and trends in predictive manufacturing systems in big data environment

[...]

Jay Lee¹, Edzel Lapira¹, Behrad Bagheri¹, Hung-An Kao¹•Institutions (1)

University of Cincinnati¹

01 Oct 2013-Manufacturing letters

TL;DR: The globalization of the world’s economies is a major challenge to local industry and it is pushing the manufacturing sector to its next transformation -predictive manufacturing as discussed by the authors, and manufacturers need to embrace emerging technologies such as advanced analytics and cyber-physical system-based approaches, to improve their efficiency and productivity.

...read moreread less

Abstract: The globalization of the world’s economies is a major challenge to local industry and it is pushing the manufacturing sector to its next transformation – predictive manufacturing. In order to become more competitive, manufacturers need to embrace emerging technologies, such as advanced analytics and cyber-physical system-based approaches, to improve their efficiency and productivity. With an aggressive push towards “Internet of Things”, data has become more accessible and ubiquitous, contributing to the big data environment. This phenomenon necessitates the right approach and tools to convert data into useful, actionable information.

...read moreread less

848 citations

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.

...read moreread less

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.

...read moreread less

681 citations

Book Chapter•DOI•

Digital Twin—The Simulation Aspect

[...]

Stefan Boschert¹, Roland Rosen¹•Institutions (1)

Siemens¹

01 Jan 2016

TL;DR: This chapter focuses on the simulation aspects of the Digital Twin, where simulation merges the physical and virtual world in all life cycle phases and enables the users to master the complexity of mechatronic systems.

...read moreread less

Abstract: The vision of the Digital Twin itself refers to a comprehensive physical and functional description of a component, product or system, which includes more or less all information which could be useful in all—the current and subsequent—lifecycle phases. In this chapter we focus on the simulation aspects of the Digital Twin. Today, modelling and simulation is a standard process in system development, e.g. to support design tasks or to validate system properties. During operation and for service first simulation-based solutions are realized for optimized operations and failure prediction. In this sense, simulation merges the physical and virtual world in all life cycle phases. Current practice already enables the users (designer, SW/HW developers, test engineers, operators, maintenance personnel, etc) to master the complexity of mechatronic systems.

...read moreread less

668 citations

Journal Article•DOI•

Design Techniques and Applications of Cyberphysical Systems: A Survey

[...]

Siddhartha Kumar Khaitan¹, James D. McCalley¹•Institutions (1)

Iowa State University¹

01 Jun 2015-IEEE Systems Journal

TL;DR: The aim of this survey is to enable researchers and system designers to get insights into the working and applications of CPSs and motivate them to propose novel solutions for making wide-scale adoption of CPS a tangible reality.

...read moreread less

Abstract: Cyberphysical systems (CPSs) are new class of engineered systems that offer close interaction between cyber and physical components. The field of CPS has been identified as a key area of research, and CPSs are expected to play a major role in the design and development of future systems. In this paper, we survey recent advancements made in the development and applications of CPSs. We classify the existing research work based on their characteristics and identify the future challenges. We also discuss the examples of prototypes of CPSs. The aim of this survey is to enable researchers and system designers to get insights into the working and applications of CPSs and motivate them to propose novel solutions for making wide-scale adoption of CPS a tangible reality.

...read moreread less

653 citations