Shop Floor Digital Twin in Smart Manufacturing: A Systematic Literature Review
Abstract
:1. Introduction
2. Materials and Methods
Planning and Execution Phases
3. Results
3.1. Reporting and Dissemination Phase
3.1.1. Digital Twin Conceptual Models
3.1.2. Benefits and Challenges of the Digital Twin
3.1.3. Digital Twin Frameworks
4. Discussion
4.1. The Hexadimensional Shop Floor Digital Twin Framework
4.1.1. Physical Layer
4.1.2. Network Layer
4.1.3. Data Integration Layer
4.1.4. Model Layer
4.1.5. Knowledge Layer
4.1.6. Application Layer
5. Conclusions
Author Contributions
Funding
Conflicts of Interest
Appendix A
ID | Authors | Title | Year | Focus | DT Conceptual Model | DT Framework | DT Benefits and Challenges | Reference |
---|---|---|---|---|---|---|---|---|
1 | Negri, Fumagalli and Macchi | A Review of the Roles of Digital Twin in CPS-based Production Systems | 2017 | The paper analyzes the definition of the digital twin concept in the literature, considering the aerospace and manufacturing domains. | X | [12] | ||
2 | Tao and Zhang | Digital Twin Shop-Floor: A New Shop-Floor Paradigm Towards Smart Manufacturing | 2017 | The concept of Digital Twin Shop-Floor (DTS) is proposed to provide an effective way to reach the physical–virtual convergence model. | X | [57] | ||
3 | Tao et al. | Digital twin-driven product design, manufacturing and service with big data | 2017 | It discusses the digital twin shop floor (DTS) as a new paradigm for product manufacturing. DTS is composed of physical shop floor, virtual shop floor, shop floor service system, and shop floor digital twin data. | X | X | [58] | |
4 | Shao and Kibira | Digital manufacturing: Requirements and challenges for implementing digital surrogates | 2018 | The “digital surrogate” concept is introduced and explores the relationships with digital thread, simulation, AI, and IoT. | X | [49] | ||
5 | Zhuang, Liu, and Xiong | Digital twin-based smart production management and control framework for the complex product assembly shop-floor | 2018 | The paper proposes a framework of digital twin-based smart production management and control approach for predicting complex product assembly shop floors. | X | [1] | ||
6 | Nikolakis et al. | The digital twin implementation for linking the virtual representation of human-based production tasks to their physical counterpart in the factory floor | 2018 | The study proposes an implementation of the digital twin approach as part of a wider cyber–physical system to enable the optimization of the planning and commissioning of human-based production processes using simulation-based approaches. | X | X | [59] | |
7 | Bao et al. | The modelling and operations for the digital twin in the context of manufacturing | 2018 | The paper develops three types of digital twins (product digital twin, process digital twin, and operation digital twin) in the manufacturing context, for simulating the state and behavior of the physical object and optimizing production process. | X | [38] | ||
8 | Ellgass et al. | A digital twin concept for manufacturing systems | 2018 | The paper develops a framework for a digital-twin-based manufacturing system, with its supported real-time simulation and optimization of shop floor. It includes four main components: virtual shop, physical shop, big data storage and management platform, and service provider. | X | [60] | ||
9 | Cheng et al. | Cyber–physical integration for moving digital factories forward towards smart manufacturing: a survey | 2018 | It provides an overview of digital twin factories. It proposes a systematical framework of cyber–physical integration for manufacturing service. | X | [20] | ||
10 | Leng et al. | Digital twin-driven manufacturing cyber–physical system for parallel controlling of smart workshop | 2018 | The paper presents a digital-twin-driven manufacturing cyber–physical system architecture. It also discusses the digital twin use in optimizing system behavior. | X | [61] | ||
11 | Kuehn | Digital twins for decision making in complex production and logistic enterprises | 2018 | The paper discusses the digital twin concept and the interactions of six steps which complete a closed loop connection (physical-to-digital-to-virtual-to-physical) between the physical world and the virtual model. | X | X | [46] | |
12 | Modoni et al. | Synchronizing physical and digital factory: Benefits and technical challenges | 2019 | The paper proposes a conceptual model to understand the digital twin by highlighting its main entities and relations. | X | X | [47] | |
13 | Park, Easwaran and Andalam | Challenges in digital twin development for cyber–physical production systems | 2019 | The paper reviews current state-of-the-art technology on tools and developments of digital twin in manufacturing and then discusses potential design challenges. | X | X | [48] | |
14 | Stark, Fresemann and Lindow | Development and operation of Digital Twins for technical systems and services | 2019 | The paper proposes two development support models that are essential for the design of digital twin solutions: the “digital Twin 8 dimension model” and digital twin design elements. | X | [11] | ||
15 | Lu et al. | Digital Twin-driven smart manufacturing: Connotation, reference model, applications and research issues | 2019 | The paper provides a literature review about the concept of digital twins in manufacturing. | X | [7] | ||
16 | Tao et al. | Digital Twin in Industry: State-of-the-Art | 2019 | The paper provides a literature review about the concept of digital twins in manufacturing. | X | [50] | ||
17 | Wang, Zhang and Zhong | A proactive material handling method for CPS enabled shop-floor | 2019 | It presents a shop floor digital twin model for simulating real-life production in a virtual environment. It discusses production KPIs and a proactive material handling strategy (CPS-PMH). | X | [51] | ||
18 | Fang et al. | Digital-Twin-Based Job Shop Scheduling Toward Smart Manufacturing | 2019 | An architecture and working principles of new job shop scheduling mode are proposed to reduce the scheduling deviation. | X | [52] | ||
19 | Chen et al. | The framework design of smart factory in discrete manufacturing industry based on cyber–physical system | 2019 | The paper explains four main charateristics of smart factory, and proposes a framework for the design of smart factory CPS-model-based digital twin. | X | [36] | ||
20 | Zhang et al. | Digital twin-enabled reconfigurable modeling for smart manufacturing systems | 2019 | This paper provides a complete set of modelling approaches for DT-based and robotics-based manufacturing systems to reconfigure manufacturing systems at different levels. | X | [53] | ||
21 | Zhang, Zhang and Yan | Digital twin-driven cyber–physical production system towards smart shop-floor | 2019 | The paper provides a reference architecture of a digital-twin-driven cyber–physical production system to enhance the transparency in the smart shop floor and to allow real-time production control. | X | [18] | ||
22 | Zhang et al. | A data- And knowledge-driven framework for digital twin manufacturing cell | 2019 | The paper introduces a data- and knowledge-driven framework for a digital twin manufacturing cell (DTMC) to support the construction of an autonomous manufacturing cell that aims to maximize the product quality and throughput. | X | [54] | ||
23 | Zhang and Zhu | Application framework of digital twin-driven product smart manufacturing system: A case study of aeroengine blade manufacturing | 2019 | The article proposes a novel application framework of a digital-twin-driven product smart manufacturing system and it analyzes its operation mechanism. | X | [55] | ||
24 | Zhang et al. | A reconfigurable modeling approach for digital twin-based manufacturing system | 2019 | It proposes a reconfigurable digital twin (RDT)-based manufacturing system for improving the operation efficency of systems for carrying out the reconfiguration production tasks, saving time, and costs. | X | [62] | ||
25 | Tao et al. | Digital Twins and Cyber–Physical Systems toward Smart Manufacturing and Industry 4.0: Correlation and Comparison | 2019 | It analyzes differences and correlation between CPS and digital twin from three different levels: the unit level, the system level (production line, shop floor, or factory), and the system of systems (SoS) level. | X | X | [63] | |
26 | Liu et al. | A digital twin-based approach for dynamic clamping and positioning of the flexible tooling system | 2019 | The paper proposes a digital-twin-based approach for dynamic clamping and positioning of the flexible tooling system. | X | [64] | ||
27 | Liu et al. | Dynamic Evaluation Method of Machining Process Planning Based on Digital Twin | 2019 | A novel digital-twin-based machining process evaluation (DT-MPPE) framework method is proposed for complex parts simulation and evaluation. | X | [65] | ||
28 | Min et al. | Machine Learning based Digital Twin Framework for Production Optimization in Petrochemical Industry | 2019 | It proposes a digital twin framework for petrochemical production control optimization based on the industrial IoT and machine learning. | X | [66] | ||
29 | Delbrügger and Rossmann | Representing adaptation options in experimentable digital twins of production systems | 2019 | The paper introduces an experimentable digital twin of the factory that tracks production and transport capabilities. The factory EDT is able to create valid production and transport plans that can be updated if the capabilities change. | X | [67] | ||
30 | Ding et al. | Defining a Digital Twin-based Cyber–Physical Production System for autonomous manufacturing in smart shop floors | 2019 | It defines a digital-twin-based cyber-physical production system (DT-CPPS) that includes a physical shop floor (PSF) configuration and a cybershop floor (CSF) configuration for a transparent management of data flow. | X | [68] | ||
31 | Park et al. | Design and implementation of a digital twin application for a connected micro smart factory | 2019 | The paper proposes a digital twin solution for simultaneously solving the cost and performance hurdles of a personalized production. | X | [69] | ||
32 | Xu et al. | A Digital-Twin-Assisted Fault Diagnosis Using Deep Transfer Learning | 2019 | The paper presents a two-phase digital-twin-assisted fault diagnosis using deep transfer learning (DFDD) which aims to make fault diagnosis more suitable for increasingly autonomous and complex manufacturing. | X | [70] | ||
33 | Kousi et al. | Digital twin for adaptation of robots’ behavior in flexible robotic assembly lines | 2019 | The study investigates the use of digital modeling techniques in hybrid production systems. The suggested digital world model infrastructure includes the dynamic real time updating of the digital twin based on sensors. | X | [71] | ||
34 | Pfeiffer, Oppelt, and Leingang | Evolution of a Digital Twin for a Steam Cracker | 2019 | The paper, through the example of a steam cracker, shows numerous aspects of an integrated application of a digital twin for process plants. | X | [72] | ||
35 | Zipper and Diedrich | Synchronization of Industrial Plant and Digital Twin | 2019 | The paper presents an architecture and an algorithm to synchronize the states of a plant and its digital twin while in the same time still providing the possibility to detect changes. | X | [73] | ||
36 | Martins, Costelha, and Neves | Shop Floor Virtualization and Industry 4.0 | 2019 | It describes the virtualization of a typical production process, the digital twin in the scope of Industry 4.0, involving different devices such as robotic arms, conveyors, automatic warehouses, and vision systems. | X | [74] | ||
37 | Park et al. | Digital twin-based cyber–physical production system architectural framework for personalized production | 2019 | The study focuses on a CPPS to prevent the degradation of production plant performance in the operation stage. | X | [75] | ||
38 | Guo et al. | Digital twin-enabled Graduation Intelligent Manufacturing System for fixedposition assembly islands | 2020 | The paper introduces the digital-twin-enabled graduation intelligent manufacturing system (DT-GiMS) for fixed-position assembly islands, real-time convergence, and synchronization among the physical layer, digital layer, and service layer. | X | [56] | ||
39 | Cheng et al. | DT-II: Digital twin enhanced Industrial Internet reference framework towards smart manufacturing | 2020 | The paper presents the implementation and operation mechanisms of digital twin industrial internet (DT-II) from three perspectives: product lifecycle level, intra-enterprise level, and inter-enterprise level. | X | [39] | ||
40 | Leng et al. | Digital twin-driven rapid reconfiguration of the automated manufacturing system via an open architecture model | 2020 | The paper discusses the digital twin system for a rapid reconfiguration process that allows to find the balance between the maximization of the productivity and the economic efficiency in terms of minimizing costs of machine moving and machine holding. | X | [76] | ||
41 | Qamsane et al. | A unified digital twin framework for real-time monitoring and evaluation of smart manufacturing systems | 2020 | The paper proposes a digital twin architecture for the real-time monitoring and evaluation of large-scale smart manufacturing systems. An application to a manufacturing flow shop is presented to illustrate the usefulness of the proposed methodology. | X | X | [77] |
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Topic | Focus | |
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1 | Digital twin conceptual models |
|
2 | Benefits and challenges of the digital twin |
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3 | Digital twin frameworks |
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Benefits | Challenges |
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Corallo, A.; Del Vecchio, V.; Lezzi, M.; Morciano, P. Shop Floor Digital Twin in Smart Manufacturing: A Systematic Literature Review. Sustainability 2021, 13, 12987. https://doi.org/10.3390/su132312987
Corallo A, Del Vecchio V, Lezzi M, Morciano P. Shop Floor Digital Twin in Smart Manufacturing: A Systematic Literature Review. Sustainability. 2021; 13(23):12987. https://doi.org/10.3390/su132312987
Chicago/Turabian StyleCorallo, Angelo, Vito Del Vecchio, Marianna Lezzi, and Paola Morciano. 2021. "Shop Floor Digital Twin in Smart Manufacturing: A Systematic Literature Review" Sustainability 13, no. 23: 12987. https://doi.org/10.3390/su132312987