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

Building a Simple Smart Factory

This thesis describes (a) the search and findings of smart factories and their enabling technologies (b) the methodology to build or retrofit a smart factory and (c) the building and operation of a simple smart factory using the methodology. A factory is an industrial site with large buildings and collection of machines, which are operated by persons to manufacture goods and services. These factories are made smart by incorporating sensing, processing, and autonomous responding capabilities. Developments in four main areas (a) sensor capabilities (b) communication capabilities (c) storing and processing huge amount of data and (d) better utilization of technology in management and further development have contributed significantly for this incorporation of smartness to factories. There is a flurry of literature in each of the above four topics and their combinations. The findings from the literature can be summarized in the following way. Sensors detect or measure a physical property and records, indicates, or otherwise responds to it. In real-time, they can make a very large amount of observations. Internet is a global computer network providing a variety of information and communication facilities and the internet of things, IoT, is the interconnection via the Internet of computing devices embedded in everyday objects, enabling them to send and receive data. Big data handling and the provision of data services are achieved through cloud computing. Due to the availability of computing power, big data can be handled and analyzed under different classifications using several different analytics. The results from these analytics can be used to trigger autonomous responsive actions that make the factory smart. Having thus comprehended the literature, a seven stepped methodology for building or retrofitting a smart factory was established. The seven steps are (a) situation analysis where the condition of the current technology is studied (b) breakdown prevention analysis (c) sensor selection (d) data transmission and storage selection (e) data processing and analytics (f) autonomous action network and (g) integration with the plant units. Experience in a cement factory highlighted the wear in a journal bearing causes plant stoppages and thus warrant a smart system to monitor and make decisions. The experience was used to develop a laboratory-scale smart factory monitoring the wear of a half-journal bearing. To mimic a plant unit a load-carrying shaft supported by two half-journal bearings were chosen and to mimic a factory with two plant units, two such shafts were chosen. Thus, there were four half-journal bearings to monitor. USB Logitech C920 webcam that operates in full-HD 1080 pixels was used to take pictures at specified intervals. These pictures are then analyzed to study the wear at these intervals. After the preliminary analysis wear versus time data for all four bearings are available. Now the ‘making smart activity’ begins. Autonomous activities are based on various analyses. The wear time data are analyzed under different classifications. Remaining life, wear coefficient specific to the bearings, weekly variation in wear and condition of adjacent bearings are some of the characteristics that can be obtained from the analytics. These can then be used to send a message to the maintenance and supplies division alerting them on the need for a replacement shortly. They can also be alerted about other bearings reaching their maturity to plan a major overhaul if needed

Machine learning based anomaly detection for industry 4.0 systems.

223 p.This thesis studies anomaly detection in industrial systems using technologies from the Fourth Industrial Revolution (4IR), such as the Internet of Things, Artificial Intelligence, 3D Printing, and Augmented Reality. The goal is to provide tools that can be used in real-world scenarios to detect system anomalies, intending to improve production and maintenance processes. The thesis investigates the applicability and implementation of 4IR technology architectures, AI-driven machine learning systems, and advanced visualization tools to support decision-making based on the detection of anomalies. The work covers a range of topics, including the conception of a 4IR system based on a generic architecture, the design of a data acquisition system for analysis and modelling, the creation of ensemble supervised and semi-supervised models for anomaly detection, the detection of anomalies through frequency analysis, and the visualization of associated data using Visual Analytics. The results show that the proposed methodology for integrating anomaly detection systems in new or existing industries is valid and that combining 4IR architectures, ensemble machine learning models, and Visual Analytics tools significantly enhances theanomaly detection processes for industrial systems. Furthermore, the thesis presents a guiding framework for data engineers and end-users

Cyberphysical network for crop monitoring and fertigation control

Mestrado de dupla diplomação com a UTFPR - Universidade Tecnológica Federal do ParanáFertigation is a cultivation technique that uses the precise application of nutrient solutions according to the requirements of the plant, environmental conditions and substrate. The use of this technique has become popular due to the advantages promoted, which include the reduction of fertilizers, phytopharmaceuticals and water consumption. However, this performance is achieved at the expense of rigorous monitoring and regulation of factors such as nutrient solutions, environmental conditions and the vegetative state of the crop. This work describes the architecture of a network based on agents and cyberphysical elements that will be implemented in a strawberry production unit by fertigation. The system must be responsible for the correct supply of water and agricultural inputs based on local information provided by sets of sensors. Each set of sensors, called a measurement node, is responsible for acquiring information around a given location. The communication of this information is carried out through a wireless network based on the LoRa protocol to a digital platform where the information from all nodes, together with meteorological data, is aggregated and processed. The result of processing this information will lead to the definition of the exact amount of nutrient solution as well as the optimization of the use of water leading to an increase in production efficiency.A fertirrigação é uma técnica de cultivo que recorre à aplicação precisa de soluções nutritivas de acordo com os requisitos da planta, condições ambientais e de substrato. A utilização desta técnica tem-se popularizado devido às vantagens promovidas onde se destacam a redução de fertilizantes, fitofármacos e consumo de água. No entanto, este desempenho é conseguido à custa de um rigoroso monitoramento e regulação de fatores tais como soluções nutritivas, condições ambientais e estado vegetativo da cultura. Este trabalho descreve a arquitetura de uma rede baseada em agentes e elementos ciberfísicos que serão implementados em uma unidade de produção de morango por fertirrigação. O sistema deve ser responsável pelo fornecimento correto de água e insumos agrícolas tendo por base informações locais fornecidas por conjuntos de sensores. Cada conjunto de sensores, chamado de nó de medida, é responsável pela aquisição da informação em torno de um determinado local. A comunicação destas informações é realizada através de uma rede sem fio baseada no protocolo LoRa até uma plataforma digital onde a informação provinda de todos os nós, juntamente com dados meteorológicos, é agregada e processada. O resultado do processamento desta informação levará à definição da quantidade exata de solução nutritiva bem como a otimização da utilização da água levando a um aumento da eficiência de produção

Utilizing industry 4.0 on the construction site : challenges and opportunities

In recent years a step change has been seen in the rate of adoption of Industry 4.0 technologies by manufacturers and industrial organisations alike. This paper discusses the current state of the art in the adoption of industry 4.0 technologies within the construction industry. Increasing complexity in onsite construction projects coupled with the need for higher productivity is leading to increased interest in the potential use of industry 4.0 technologies. This paper discusses the relevance of the following key industry 4.0 technologies to construction: data analytics and artificial intelligence; robotics and automation; buildings information management; sensors and wearables; digital twin and industrial connectivity. Industrial connectivity is a key aspect as it ensures that all Industry 4.0 technologies are interconnected allowing the full benefits to be realized. This paper also presents a research agenda for the adoption of Industry 4.0 technologies within the construction sector; a three-phase use of intelligent assets from the point of manufacture up to after build and a four staged R&D process for the implementation of smart wearables in a digital enhanced construction site

Technologies for safe and resilient earthmoving operations: A systematic literature review

Resilience engineering relates to the ability of a system to anticipate, prepare, and respond to predicted and unpredicted disruptions. It necessitates the use of monitoring and object detection technologies to ensure system safety in excavation systems. Given the increased investment and speed of improvement in technologies, it is necessary to review the types of technology available and how they contribute to excavation system safety. A systematic literature review was conducted which identified and classified the existing monitoring and object detection technologies, and introduced essential enablers for reliable and effective monitoring and object detection systems including: 1) the application of multisensory and data fusion approaches, and 2) system-level application of technologies. This study also identified the developed functionalities for accident anticipation, prevention and response to safety hazards during excavation, as well as those that facilitate learning in the system. The existing research gaps and future direction of research have been discussed

Emerging Informatics

The book on emerging informatics brings together the new concepts and applications that will help define and outline problem solving methods and features in designing business and human systems. It covers international aspects of information systems design in which many relevant technologies are introduced for the welfare of human and business systems. This initiative can be viewed as an emergent area of informatics that helps better conceptualise and design new world-class solutions. The book provides four flexible sections that accommodate total of fourteen chapters. The section specifies learning contexts in emerging fields. Each chapter presents a clear basis through the problem conception and its applicable technological solutions. I hope this will help further exploration of knowledge in the informatics discipline

Design of Wireless Sensors for IoT with Energy Storage and Communication Channel Heterogeneity

Autonomous Wireless Sensors (AWSs) are at the core of every Wireless Sensor Network (WSN). Current AWS technology allows the development of many IoT-based applications, ranging from military to bioengineering and from industry to education. The energy optimization of AWSs depends mainly on: Structural, functional, and application specifications. The holistic design methodology addresses all the factors mentioned above. In this sense, we propose an original solution based on a novel architecture that duplicates the transceivers and also the power source using a hybrid storage system. By identifying the consumption needs of the transceivers, an appropriate methodology for sizing and controlling the power flow for the power source is proposed. The paper emphasizes the fusion between information, communication, and energy consumption of the AWS in terms of spectrum information through a set of transceiver testing scenarios, identifying the main factors that influence the sensor node design and their inter-dependencies. Optimization of the system considers all these factors obtaining an energy efficient AWS, paving the way towards autonomous sensors by adding an energy harvesting element to them

Design of Wireless Sensors for IoT with Energy Storage and Communication Channel Heterogeneity

Autonomous Wireless Sensors (AWSs) are at the core of every Wireless Sensor Network (WSN). Current AWS technology allows the development of many IoT-based applications, ranging from military to bioengineering and from industry to education. The energy optimization of AWSs depends mainly on: Structural, functional, and application specifications. The holistic design methodology addresses all the factors mentioned above. In this sense, we propose an original solution based on a novel architecture that duplicates the transceivers and also the power source using a hybrid storage system. By identifying the consumption needs of the transceivers, an appropriate methodology for sizing and controlling the power flow for the power source is proposed. The paper emphasizes the fusion between information, communication, and energy consumption of the AWS in terms of spectrum information through a set of transceiver testing scenarios, identifying the main factors that influence the sensor node design and their inter-dependencies. Optimization of the system considers all these factors obtaining an energy efficient AWS, paving the way towards autonomous sensors by adding an energy harvesting element to them

Low-cost sensors technologies for monitoring sustainability and safety issues in mining activities: advances, gaps, and future directions in the digitalization for smart mining

Nowadays, monitoring aspects related to sustainability and safety in mining activities worldwide are a priority, to mitigate socio-environmental impacts, promote efficient use of water, reduce carbon footprint, use renewable energies, reduce mine waste, and minimize the risks of accidents and fatalities. In this context, the implementation of sensor technologies is an attractive alternative for the mining industry in the current digitalization context. To have a digital mine, sensors are essential and form the basis of Industry 4.0, and to allow a more accelerated, reliable, and massive digital transformation, low-cost sensor technology solutions may help to achieve these goals. This article focuses on studying the state of the art of implementing low-cost sensor technologies to monitor sustainability and safety aspects in mining activities, through the review of scientific literature. The methodology applied in this article was carried out by means of the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines and generating science mapping. For this, a methodological procedure of three steps was implemented: (i) Bibliometric analysis as a quantitative method, (ii) Systematic review of literature as a qualitative method, and (iii) Mixed review as a method to integrate the findings found in (i) and (ii). Finally, according to the results obtained, the main advances, gaps, and future directions in the implementation of low-cost sensor technologies for use in smart mining are exposed. Digital transformation aspects for data measurement with low-cost sensors by real-time monitoring, use of wireless network systems, artificial intelligence, machine learning, digital twins, and the Internet of Things, among other technologies of the Industry 4.0 era are discussed.The authors are indebted to the projects PID2021-126405OB-C31 and PID2021-126405OB-C32 funded by FEDER funds—A Way to Make Europe and Spanish Ministry of Economy and Competitiveness MICIN/AEI/10.13039/501100011033/. The financial support of the Research Department of the Catholic University of Temuco and the Civil Engineering Department of the University of Castilla-La Mancha is also appreciated.Peer ReviewedPostprint (published version