Conceiving a Digital Twin for a Flexible Manufacturing System

Digitization and virtualization represent key factors in the era of Industry 4.0. Digital twins (DT) can certainly contribute to increasing the efficiency of various productive sectors as they can contribute to monitoring, managing, and improvement of a product or process throughout its life cycle. Although several works deal with DTs, there are gaps regarding the use of this technology when a Flexible Manufacturing System (FMS) is used. Existing work, for the most part, is concerned with simulating the progress of manufacturing without providing key production data in real-time. Still, most of the solutions presented in the literature are relatively expensive and may be difficult to implement in most companies, due to their complexity. In this work, the digital twin of an FMS is conceived. The specific module of an ERP (Enterprise Resources Planning) system is used to digitize the physical entity. Production data is entered according to tryouts performed in the FMS. Sensors installed in the main components of the FMS, CNC (computer numerical control) lathe, robotic arm, and pallet conveyor send information in real-time to the digital entity. The results show that simulations using the digital twin present very satisfactory results compared to the physical entity. In time, information such as production rate, queue management, feedstock, equipment, and pallet status can be easily accessed by operators and managers at any time during the production process, confirming the MES (manufacture execution system) efficiency. The low-cost hardware and software used in this work showed its feasibility. The DT created represents the initial step towards designing a metaverse solution for the manufacturing unit in question, which should operate in the near future as a smart and autonomous factory model.

Automated summary

Digitization and virtualization are key factors in the era of Industry 4.0. Digital twins can increase the efficiency of various productive sectors, but there are challenges in using this technology in a Flexible Manufacturing System (FMS). Existing solutions are often expensive and complex to implement. This study presents a low-cost digital twin method for FMS, which uses an ERP system module to digitize the physical entity and sensors to provide real-time information, improving production efficiency and management.