The cyber-physical e-machine manufacturing system : virtual engineering for complete lifecycle support

Electric machines (e-machines) will form a fundamental part of the powertrain of the future. Automotive manufacturers are keen to develop emachine manufacturing and assembly knowledge in-house. An on-going project, which aims to deliver an e-machine pilot assembly line, is being supported by a set of virtual engineering tools developed by the Automation Systems Group at the University of Warwick. Although digital models are a useful design aid providing visualization and simulation, the opportunity being exploited in this research paper is to have a common model throughout the lifecycle of both the manufacturing system and the product. The vision is to have a digital twin that is consistent with the real system and not just used in the early design and deployment phases. This concept, commonly referred to as Cyber Physical Systems (CPS), is key to realizing efficient system reconfigurability to support alternative product volumes and mixes. These tools produce modular digital models that can be rapidly modified preventing the simulation, test, and modification processes forming a bottleneck to the development lifecycles. In addition, they add value at more mature phases when, for example, a high volume line based on the pilot is created as the same models can be reused and modified as required. This research paper therefore demonstrates how the application of the virtual engineering tools support the development of a CPS using an e-machine assembly station as a case study. The main contribution of the work is to further validate the CPS philosophy by extending the concept into practical applications in pilot production systems with prototype products

Asset Administration Shell as an interoperable enabler of Industry 4.0 software architectures: a case study

In recent years, the discipline of Digital Transformation in manufacturing companies turned out to be a hot topic of research debate, which allowed the design and introduction of new technologies and tools able to exploit the potential of the data produced by the shop floor assets. This increased interest in data generation and management has however highlighted a crucial issue about the lack of standardised models and structures to share these data and ensure interoperability. Among the several concepts proposed by the recent initiatives devoted to solving or mitigating this issue, Asset Administration Shell (AAS) is increasing in popularity, given its potential in providing standardised and modular information about the assets and events represented. This paper deals with a demonstration of the easiness of integration of AAS in pre-existing software architecture, allowing higher flexibility and a better understanding of the ongoing processes: a production line has been indeed entirely represented with modular AAS metamodels and it has been used to feed a Digital Model representing the line configuration. The use case proposed proves the effectiveness of the obtained solution when used for virtual commissioning operations

GAS TURBINE PERFORMANCE DIGITAL TWIN FOR REAL-TIME EMBEDDED SYSTEMS

This contribution reports on the development of Performance Digital Twin for industrial Small Gas Turbines. The objective of this study was the development of automation systems with control and monitoring functionalities, capable of addressing the requirements of future gas turbine plants for increased availability and reliability by use of Digital Twin technology. The project explored development of Performance Digital Twin based on Real-Time Embedded computing, which can be leveraged with Internet-of-Things (IOT) Cloud Platforms. The proposed solution was provided in a form of modular software for a range of hardware platforms, with corresponding functionalities to support advanced control, monitoring, tracking and diagnostics strategies. The developed Digital Twin was designed to be used in off-line mode to assist the software commissioning process and in on-line mode to enable early detection of degradation and fault modes typical for gas path components. The Performance Digital Twin is based on a dynamic gas turbine model which was augmented with a Kalman tuner to enable performance tracking of physical assets. To support heterogeneity of gas turbine Distributed Control Systems (DCS), this project explored deployment of Digital Twin on multiple platforms. In the paper, we discuss model-based design techniques and tools specific for continuous, discrete and hybrid systems. The hybrid solution was deployed on PC-based platform and integrated with engine Distributed Control System in the field. Monitoring of gas turbine Performance Digital Twin functionalities has been established via Remote Monitoring System (STA-RMS). Assessment of deployed solution has been carried out and we present results from the field trial in this paper. The discrete solution was deployed on a range of Programable Logical Controller (PLC) platforms and has been tested by integrating Digital Twin in virtual engine Distributed Control System network. The Performance Digital Twin was embedded in Single Master PLC and Master-Slave PLC configurations, and we present results from the system testing using virtual gas turbine assets. The IoT Platform MindSphere was integrated within virtual engine network, and in this contribution, we explore expansion of the developed system with Cloud based applications and services

Iot open-source architecture for the maintenance of building facilities

none6noThe introduction of the Internet of Things (IoT) in the construction industry is evolving facility maintenance (FM) towards predictive maintenance development. Predictive maintenance of building facilities requires continuously updated data on construction components to be acquired through integrated sensors. The main challenges in developing predictive maintenance tools for building facilities is IoT integration, IoT data visualization on the building 3D model and implementation of maintenance management system on the IoT and building information modeling (BIM). The current 3D building models do not fully interact with IoT building facilities data. Data integration in BIM is challenging. The research aims to integrate IoT alert systems with BIM models to moni-tor building facilities during the operational phase and to visualize building facilities’ conditions virtually. To provide efficient maintenance services for building facilities this research proposes an integration of a digital framework based on IoT and BIM platforms. Sensors applied in the building systems and IoT technology on a cloud platform with opensource tools and standards enable monitoring of real-time operation and detecting of different kinds of faults in case of malfunction or failure, therefore sending alerts to facility managers and operators. Proposed preventive maintenance methodology applied on a proof-of-concept heating, ventilation and air conditioning (HVAC) plant adopts open source IoT sensor networks. The results show that the integrated IoT and BIM dashboard framework and implemented building structures preventive maintenance methodology are applicable and promising. The automated system architecture of building facilities is intended to provide a reliable and practical tool for real-time data acquisition. Analysis and 3D visualization to support intelligent monitoring of the indoor condition in buildings will enable the facility managers to make faster and better decisions and to improve building facilities’ real time monitoring with fallouts on the maintenance timeliness.openVilla V.; Naticchia B.; Bruno G.; Aliev K.; Piantanida P.; Antonelli D.Villa, V.; Naticchia, B.; Bruno, G.; Aliev, K.; Piantanida, P.; Antonelli, D

The AlfaCrux CubeSat mission description and early results

On 1 April 2022, the AlfaCrux CubeSat was launched by the Falcon 9 Transporter-4 mission, the fourth SpaceX dedicated smallsat rideshare program mission, from Space Launch Complex 40 at Cape Canaveral Space Force Station in Florida into a Sun-synchronous orbit at 500 km. AlfaCrux is an amateur radio and educational mission to provide learning and scientific benefits in the context of small satellite missions. It is an opportunity for theoretical and practical learning about the technical management, systems design, communication, orbital mechanics, development, integration, and operation of small satellites. The AlfaCrux payload, a software-defined radio hardware, is responsible for two main services, which are a digital packet repeater and a store-and-forward system. In the ground segment, a cloud-computing-based command and control station has been developed, together with an open access online platform to access and visualize the main information of the AlfaCrux telemetry and user data and experiments. It also becomes an in-orbit database reference to be used for different studies concerned with, for instance, radio propagation, attitude reconstruction, data-driven calibration algorithms for satellite sensors, among others. In this context, this paper describes the AlfaCrux mission, its main subsystems, and the achievements obtained in the early orbit phase. Scientific and engineering assessments conducted with the spacecraft operations to tackle unexpected behaviors in the ground station and also to better understand the space environment are also presented and discussed.Fundação de Apoio à Pesquisa del Distrito Federal (FAPDF), Brasil | Ref. N/

Transdisciplinary Evaluation of Simulation Software for Industry 4.0 Assembly Lines

Industry 4.0 is driving the revolution of manufacturing processes by combining innovative technologies and new interaction paradigms among systems and operators. In particular, the layout, tasks and work sequences of assembly lines are designed according to several transdisciplinary Design Principles (DPs), such as process efficiency, product quality, ergonomics, safety and operators’ workload. A large variety of simulation software can be employed for evaluations. However, the related ability to assess multidisciplinary factors must be evaluated. The paper aims to provide a framework for guiding the assessment of simulation software in the context of Industry 4.0 assembly lines. Process requirements are first analyzed and mapped to select DPs, prioritized according to design goals by an analytical hierarchy process. Then, suitable simulation software is determined accordingly, and the virtual model is realized. Finally, the possibility of the software to provide meaningful elaborations for the selected DPs is assessed. The framework has been tested on a prototypal Industry 4.0 assembly line composed of automated logistic systems, cobots and systems to guide the execution of tasks. The line has been modeled in Siemens Process Simulate, analyzing the completeness and appropriateness of the functionalities of this software according to the defined DPs

Local Digital Twin-based control of a cobot-assisted assembly cell based on Dispatching Rules

In the context of an increasing digitalization of production processes, Digital Twins (DT) are emerging as new simulation paradigm for manufacturing, which leads to potential advances in the production planning and control of production systems. In particular, DT can support production control activities thanks to the bidirectional connection in near real-time with the modeled system. Research on DT for production planning and control of automated systems is already ongoing, but manual and semi-manual systems did not receive the same attention. In this paper, a novel framework focused on a local DT is proposed to control a cobot-assisted assembly cell. The DT replicates the behavior of the cell, providing accurate predictions of its performances in alternative scenarios. Then, building on these predicted estimates, the controller selects, among different dispatching rules, the most appropriate one to pursue different performance objectives. This has been proven beneficial through a simulation assessment of the whole assembly line considered as testbed