OpenTwins: An open-source framework for the development of next-gen compositional digital twins

Funding for open access charge: Universidad de Málaga / CBU

Frameworks for data-driven quality management in cyber-physical systems for manufacturing: A systematic review

Recent advances in the manufacturing industry have enabled the deployment of Cyber-Physical Systems (CPS) at scale. By utilizing advanced analytics, data from production can be analyzed and used to monitor and improve the process and product quality. Many frameworks for implementing CPS have been developed to structure the relationship between the digital and the physical worlds. However, there is no systematic review of the existing frameworks related to quality management in manufacturing CPS. Thus, our study aims at determining and comparing the existing frameworks. The systematic review yielded 38 frameworks analyzed regarding their characteristics, use of data science and Machine Learning (ML), and shortcomings and open research issues. The identified issues mainly relate to limitations in cross-industry/cross-process applicability, the use of ML, big data handling, and data security.publishedVersio

Digital Twin Models in Industrial Operations: A Systematic Literature Review

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Digital Twins:State of the Art Theory and Practice, Challenges, and Open Research Questions

Digital Twin was introduced over a decade ago, as an innovative all-encompassing tool, with perceived benefits including real-time monitoring, simulation and forecasting. However, the theoretical framework and practical implementations of digital twins (DT) are still far from this vision. Although successful implementations exist, sufficient implementation details are not publicly available, therefore it is difficult to assess their effectiveness, draw comparisons and jointly advance the DT methodology. This work explores the various DT features and current approaches, the shortcomings and reasons behind the delay in the implementation and adoption of digital twin. Advancements in machine learning, internet of things and big data have contributed hugely to the improvements in DT with regards to its real-time monitoring and forecasting properties. Despite this progress and individual company-based efforts, certain research gaps exist in the field, which have caused delay in the widespread adoption of this concept. We reviewed relevant works and identified that the major reasons for this delay are the lack of a universal reference framework, domain dependence, security concerns of shared data, reliance of digital twin on other technologies, and lack of quantitative metrics. We define the necessary components of a digital twin required for a universal reference framework, which also validate its uniqueness as a concept compared to similar concepts like simulation, autonomous systems, etc. This work further assesses the digital twin applications in different domains and the current state of machine learning and big data in it. It thus answers and identifies novel research questions, both of which will help to better understand and advance the theory and practice of digital twins

Digital-Twins towards Cyber-Physical Systems: A Brief Survey

Cyber-Physical Systems (CPS) are integrations of computation and physical processes. Physical processes are monitored and controlled by embedded computers and networks, which frequently have feedback loops where physical processes affect computations and vice versa. To ease the analysis of a system, the costly physical plants can be replaced by the high-fidelity virtual models that provide a framework for Digital-Twins (DT). This paper aims to briefly review the state-of-the-art and recent developments in DT and CPS. Three main components in CPS, including communication, control, and computation, are reviewed. Besides, the main tools and methodologies required for implementing practical DT are discussed by following the main applications of DT in the fourth industrial revolution through aspects of smart manufacturing, sixth wireless generation (6G), health, production, energy, and so on. Finally, the main limitations and ideas for future remarks are talked about followed by a short guideline for real-world application of DT towards CPS

Принципы создания прототипа цифрового двойника процесса алкилирования бензола пропиленом на основе нейронной сети

Objectives. To identify the principles of creating digital twins of an operating technological unit along the example of the process of liquid-phase alkylation of benzene with propylene, and to establish the sequence of stages of formation of a digital twin, which can be applied to optimize oil and gas chemical production.Methods. The chemical and technological system consisting of reactor, mixer, heat exchangers, separator, rectification columns, and pump is considered as a complex high-level system. Data was acquired in order to describe the functioning of the isopropylbenzene production unit. The main parameters of the process were calculated by simulation modeling using UniSim® Design software. A neural network model was developed and trained. The influence of various factors of the reaction process of alkylation, separation of reaction products, and evaluation of economic factors providing market interest of the industrial process was also considered. The adequacy of calculations was determined by statistics methods. A microcontroller prototype of the process was created.Results. A predictive neural network model and its creation algorithm for the process of benzene alkylation was developed. This model can be loaded into a microcontroller to allow for real-time determination of the economic efficiency of plant operation and automated optimization depending on the following factors: composition of incoming raw materials; the technological mode of the plant; the temperature mode of the process; and the pressure in the reactor.Conclusions. The model of a complex chemicotechnological system of cumene production, created and calibrated on the basis of long-term industrial data and the results of calculations of the output parameters, enables the parameters of the technological process of alkylation to be calculated (yield of reaction products, energy costs, conditional profit at the output of finished products). During the development of a hardware-software prototype, adapted to the operation of the real plant, the principles and stages of creating a digital twin of the operating systems of chemical technology industries were identified and formulated.Цели. Выявление принципов создания цифровых двойников реально действующей технологической установки на примере процесса жидкофазного алкилирования бензола пропиленом и установление последовательности этапов формирования цифрового двойника, которая может быть применима для оптимизации работы нефтегазохимического производства.Методы. Рассмотрена в целом химико-технологическая система, состоящая из реактора, смесителя, теплообменников, сепаратора, ректификационных колонн и насоса, как система высокого уровня. Выполнен сбор данных, описывающих функционирование установки получения изопропилбензола алкилированием бензола пропиленом путем расчета основных параметров процесса с помощью имитационного моделирования с применением специализированного программного обеспечения UniSim® Design. Разработана и обучена нейросетевая модель, учитывающая влияние различных факторов реакционного процесса алкилирования, разделения продуктов реакции и оценки экономических факторов, обеспечивающих рыночную привлекательность рассматриваемого промышленного процесса. Определена адекватность результатов расчетов оптимальных параметров процесса методами математической статистики. Создан прототип цифрового двойника процесса, реализованной на микроконтроллере.Результаты. Создана прогностическая нейросетевая модель и алгоритм ее построения для процесса алкилирования бензола пропиленом, позволяющая при загрузке ее в микроконтроллер обеспечить в режиме реального времени определение экономической эффективности работы установки и автоматическую оптимизацию работы установки в зависимости от состава поступающего сырья технологического режима системы, температурного режима проведения процесса и давления в реакторе.Выводы. Созданная модель сложной химико-технологической системы производства кумола, откалиброванная на основании промышленных данных длительного пробега технологической установки и результатов расчетов выходных параметров процесса при помощи нейронной сети, реализованной на микроконтроллере, позволяет рассчитать параметры технологического процесса алкилирования (выход продуктов реакции, энергетические затраты, условную прибыль при выпуске готовой продукции). В процессе разработки прототипа программно-аппаратного комплекса управления установкой алкилирования бензола пропиленом на основе данных, адаптированных к работе реальной установки, были выявлены и сформулированы принципы и этапы создания цифрового двойника производственных систем отраслей химической технологии

Application of machine learning algorithm in the sheet metal industry : an exploratory case study

This study solved a practical problem in a case in the sheet metal industry using machine learning and deep learning algorithms. The problem in the case company was related to detecting the minimum gaps between components, which were produced after the punching operation of a metal sheet. Due to the narrow gaps between the components, an automated sheer machine could not grip the rest of the sheet skeleton properly after the punching operation. This resulted in some of the scraped sheet on the worktable being left behind, which needed a human operator to intervene. This caused an extra trigger to the production line that resulted in a break in production. To solve this critical problem, the relevant images of the components and the gaps between them were analyzed using machine learning and deep learning techniques. The outcome of this study contributed to eliminating the production bottleneck by optimizing the gaps between the punched components. This optimization process facilitated the easy and safe movement of the gripper machine and contributed to minimizing the sheet waste.© 2021 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group. This is an Open Access article distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives License (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is properly cited, and is not altered, transformed, or built upon in any way.fi=vertaisarvioitu|en=peerReviewed