A New Concept of Digital Twin Supporting Optimization and Resilience of Factories of the Future

In the context of Industry 4.0, a growing use is being made of simulation-based decision-support tools commonly named Digital Twins. Digital Twins are replicas of the physical manufacturing assets, providing means for the monitoring and control of individual assets. Although extensive research on Digital Twins and their applications has been carried out, the majority of existing approaches are asset specific. Little consideration is made of human factors and interdependencies between different production assets are commonly ignored. In this paper, we address those limitations and propose innovations for cognitive modeling and co-simulation which may unleash novel uses of Digital Twins in Factories of the Future. We introduce a holistic Digital Twin approach, in which the factory is not represented by a set of separated Digital Twins but by a comprehensive modeling and simulation capacity embracing the full manufacturing process including external network dependencies. Furthermore, we introduce novel approaches for integrating models of human behavior and capacities for security testing with Digital Twins and show how the holistic Digital Twin can enable new services for the optimization and resilience of Factories of the Future. To illustrate this approach, we introduce a specific use-case implemented in field of Aerospace System Manufacturing.The present work was developed under the EUREKA–ITEA3 Project CyberFactory#1 (ITEA-17032), co-funded by Project CyberFactory#1PT (ANI|P2020 40124), from FEDER Funds through NORTE2020 program and from National Funds through FCT under the project UID/EEA/00760/2019 and by the Federal Ministry of Education and Research (BMBF, Germany, funding No. 01IS18061C).info:eu-repo/semantics/publishedVersio

Digital Twins and the Future of their Use Enabling Shift Left and Shift Right Cybersecurity Operations

Digital Twins (DTs), optimize operations and monitor performance in Smart Critical Systems (SCS) domains like smart grids and manufacturing. DT-based cybersecurity solutions are in their infancy, lacking a unified strategy to overcome challenges spanning next three to five decades. These challenges include reliable data accessibility from Cyber-Physical Systems (CPS), operating in unpredictable environments. Reliable data sources are pivotal for intelligent cybersecurity operations aided with underlying modeling capabilities across the SCS lifecycle, necessitating a DT. To address these challenges, we propose Security Digital Twins (SDTs) collecting realtime data from CPS, requiring the Shift Left and Shift Right (SLSR) design paradigm for SDT to implement both design time and runtime cybersecurity operations. Incorporating virtual CPS components (VC) in Cloud/Edge, data fusion to SDT models is enabled with high reliability, providing threat insights and enhancing cyber resilience. VC-enabled SDT ensures accurate data feeds for security monitoring for both design and runtime. This design paradigm shift propagates innovative SDT modeling and analytics for securing future critical systems. This vision paper outlines intelligent SDT design through innovative techniques, exploring hybrid intelligence with data-driven and rule-based semantic SDT models. Various operational use cases are discussed for securing smart critical systems through underlying modeling and analytics capabilities.Comment: IEEE Submitted Paper: Trust, Privacy and Security in Intelligent Systems, and Application

Digital twins: a survey on enabling technologies, challenges, trends and future prospects

Digital Twin (DT) is an emerging technology surrounded by many promises, and potentials to reshape the future of industries and society overall. A DT is a system-of-systems which goes far beyond the traditional computer-based simulations and analysis. It is a replication of all the elements, processes, dynamics, and firmware of a physical system into a digital counterpart. The two systems (physical and digital) exist side by side, sharing all the inputs and operations using real-time data communications and information transfer. With the incorporation of Internet of Things (IoT), Artificial Intelligence (AI), 3D models, next generation mobile communications (5G/6G), Augmented Reality (AR), Virtual Reality (VR), distributed computing, Transfer Learning (TL), and electronic sensors, the digital/virtual counterpart of the real-world system is able to provide seamless monitoring, analysis, evaluation and predictions. The DT offers a platform for the testing and analysing of complex systems, which would be impossible in traditional simulations and modular evaluations. However, the development of this technology faces many challenges including the complexities in effective communication and data accumulation, data unavailability to train Machine Learning (ML) models, lack of processing power to support high fidelity twins, the high need for interdisciplinary collaboration, and the absence of standardized development methodologies and validation measures. Being in the early stages of development, DTs lack sufficient documentation. In this context, this survey paper aims to cover the important aspects in realization of the technology. The key enabling technologies, challenges and prospects of DTs are highlighted. The paper provides a deep insight into the technology, lists design goals and objectives, highlights design challenges and limitations across industries, discusses research and commercial developments, provides its applications and use cases, offers case studies in industry, infrastructure and healthcare, lists main service providers and stakeholders, and covers developments to date, as well as viable research dimensions for future developments in DTs

An artificial intelligence-based collaboration approach in industrial IoT manufacturing : key concepts, architectural extensions and potential applications

The digitization of manufacturing industry has led to leaner and more efficient production, under the Industry 4.0 concept. Nowadays, datasets collected from shop floor assets and information technology (IT) systems are used in data-driven analytics efforts to support more informed business intelligence decisions. However, these results are currently only used in isolated and dispersed parts of the production process. At the same time, full integration of artificial intelligence (AI) in all parts of manufacturing systems is currently lacking. In this context, the goal of this manuscript is to present a more holistic integration of AI by promoting collaboration. To this end, collaboration is understood as a multi-dimensional conceptual term that covers all important enablers for AI adoption in manufacturing contexts and is promoted in terms of business intelligence optimization, human-in-the-loop and secure federation across manufacturing sites. To address these challenges, the proposed architectural approach builds on three technical pillars: (1) components that extend the functionality of the existing layers in the Reference Architectural Model for Industry 4.0; (2) definition of new layers for collaboration by means of human-in-the-loop and federation; (3) security concerns with AI-powered mechanisms. In addition, system implementation aspects are discussed and potential applications in industrial environments, as well as business impacts, are presented

Standardization Framework for Sustainability from Circular Economy 4.0

The circular economy (CE) is widely known as a way to implement and achieve sustainability, mainly due to its contribution towards the separation of biological and technical nutrients under cyclic industrial metabolism. The incorporation of the principles of the CE in the links of the value chain of the various sectors of the economy strives to ensure circularity, safety, and efficiency. The framework proposed is aligned with the goals of the 2030 Agenda for Sustainable Development regarding the orientation towards the mitigation and regeneration of the metabolic rift by considering a double perspective. Firstly, it strives to conceptualize the CE as a paradigm of sustainability. Its principles are established, and its techniques and tools are organized into two frameworks oriented towards causes (cradle to cradle) and effects (life cycle assessment), and these are structured under the three pillars of sustainability, for their projection within the proposed framework. Secondly, a framework is established to facilitate the implementation of the CE with the use of standards, which constitute the requirements, tools, and indicators to control each life cycle phase, and of key enabling technologies (KETs) that add circular value 4.0 to the socio-ecological transition

Digitalization of Building Site Management in the Construction Industry

 With Industry 4.0, a digital transformation has started in the construction industry. However, 4.0 technologies have difficulties in the integration of digital systems due to the diversity and complexity of the processes in the construction industry. Multidisciplinary work in architectural projects and the need for high productivity require digital renovation planning in the construction industry. The application of the technologies that emerged because of digital transformation on the building site has revealed the concept of the smart building site. Within the framework of many current issues such as the smart building site, the digital transformation on the building sites needs to be explored and defined. In this study, a bibliometric analysis was carried out on the publications in this field by evaluating the transformation potentials of the digitalized building sites of the future. Academic publications that will raise awareness in the improvement of building site management and the development of digital systems have been determined. Conceptual integrity was created by seeing the research gap for digitalization in building site management and it was aimed to guide researchers in future studies. As a result, based on the research area analysis and the diversity of academic publications, it was seen that the studies in the field of architecture were insufficient compared to the engineering fields

Digital Twins in Industry

Digital Twins in Industry is a compilation of works by authors with specific emphasis on industrial applications. Much of the research on digital twins has been conducted by the academia in both theoretical considerations and laboratory-based prototypes. Industry, while taking the lead on larger scale implementations of Digital Twins (DT) using sophisticated software, is concentrating on dedicated solutions that are not within the reach of the average-sized industries. This book covers 11 chapters of various implementations of DT. It provides an insight for companies who are contemplating the adaption of the DT technology, as well as researchers and senior students in exploring the potential of DT and its associated technologies

Mist and Edge Computing Cyber-Physical Human-Centered Systems for Industry 5.0: A Cost-Effective IoT Thermal Imaging Safety System

While many companies worldwide are still striving to adjust to Industry 4.0 principles, the transition to Industry 5.0 is already underway. Under such a paradigm, Cyber-Physical Human-centered Systems (CPHSs) have emerged to leverage operator capabilities in order to meet the goals of complex manufacturing systems towards human-centricity, resilience and sustainability. This article first describes the essential concepts for the development of Industry 5.0 CPHSs and then analyzes the latest CPHSs, identifying their main design requirements and key implementation components. Moreover, the major challenges for the development of such CPHSs are outlined. Next, to illustrate the previously described concepts, a real-world Industry 5.0 CPHS is presented. Such a CPHS enables increased operator safety and operation tracking in manufacturing processes that rely on collaborative robots and heavy machinery. Specifically, the proposed use case consists of a workshop where a smarter use of resources is required, and human proximity detection determines when machinery should be working or not in order to avoid incidents or accidents involving such machinery. The proposed CPHS makes use of a hybrid edge computing architecture with smart mist computing nodes that processes thermal images and reacts to prevent industrial safety issues. The performed experiments show that, in the selected real-world scenario, the developed CPHS algorithms are able to detect human presence with low-power devices (with a Raspberry Pi 3B) in a fast and accurate way (in less than 10 ms with a 97.04% accuracy), thus being an effective solution that can be integrated into many Industry 5.0 applications. Finally, this article provides specific guidelines that will help future developers and managers to overcome the challenges that will arise when deploying the next generation of CPHSs for smart and sustainable manufacturing.Comment: 32 page

Holistic Security and Safety for Factories of the Future

The accelerating transition of traditional industrial processes towards fully automated and intelligent manufacturing is being witnessed in almost all segments. This major adoption of enhanced technology and digitization processes has been originally embraced by the Factories of the Future and Industry 4.0 initiatives. The overall aim is to create smarter, more sustainable, and more resilient future-oriented factories. Unsurprisingly, introducing new production paradigms based on technologies such as machine learning (ML), the Internet of Things (IoT), and robotics does not come at no cost as each newly incorporated technique poses various safety and security challenges. Similarly, the integration required between these techniques to establish a unified and fully interconnected environment contributes to additional threats and risks in the Factories of the Future. Accumulating and analyzing seemingly unrelated activities, occurring simultaneously in different parts of the factory, is essential to establish cyber situational awareness of the investigated environment. Our work contributes to these efforts, in essence by envisioning and implementing the SMS-DT, an integrated platform to simulate and monitor industrial conditions in a digital twin-based architecture. SMS-DT is represented in a three-tier architecture comprising the involved data and control flows: edge, platform, and enterprise tiers. The goal of our platform is to capture, analyze, and correlate a wide range of events being tracked by sensors and systems in various domains of the factory. For this aim, multiple components have been developed on the basis of artificial intelligence to simulate dominant aspects in industries, including network analysis, energy optimization, and worker behavior. A data lake was also used to store collected information, and a set of intelligent services was delivered on the basis of innovative analysis and learning approaches. Finally, the platform was tested in a textile industry environment and integrated with its ERP system. Two misuse cases were simulated to track the factory machines, systems, and people and to assess the role of SMS-DT correlation mechanisms in preventing intentional and unintentional actions. The results of these misuse case simulations showed how the SMS-DT platform can intervene in two domains in the first scenario and three in the second one, resulting in correlating the alerts and reporting them to security operators in the multi-domain intelligent correlation dashboard.The present work has been developed under the EUREKA ITEA3 Project Cyber-Factory#1 (ITEA-17032) and Project CyberFactory#1PT (ANI—P2020 40124) co-funded by Portugal 2020. Furthermore, this work also received funding from the project UIDB/00760/2020.info:eu-repo/semantics/publishedVersio