Real-Time asset tracking; a starting point for Digital Twin implementation in Manufacturing

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Real-Time asset tracking; a starting point for Digital Twin implementation 28th CIRP Design Mayfor 2018, Nantes, Twin France implementation Real-Time asset tracking; a starting point Digital inConference, Manufacturing in Manufacturing A new methodology to analyze the functional andA.physical architecture of Kousay Samir*, Antonio Maffei, Mauro Onori Samir*, Antonio Maffei,Engineering, Mauro A. Onori existing products for an assembly oriented product familySweden identification KTH RoyalKousay Institute of Technology, Department of Production 10044 Stockholm, * Corresponding author. Tel.:KTH +46761039860; E-mail address: [email protected] Royal Institute of Technology, Department of Production Engineering, 10044 Stockholm, Sweden

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat

* Corresponding author. Tel.: +46761039860; E-mail address: [email protected]

Abstract

École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

*Abstract Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]

Mass customization and shortening product life cycles pose a heightened set of requirement on modern production systems. Fast response to changingand conditions hasproduct been found to be apose key atoheightened competitive for manufacturing firms. In order to cope Mass customization shortening life cycles setadvantage of requirement on modern production systems. Fast with this, modern firms are entering in the fourth industrial revolution. Smart pieces of equipment, based on ubiquitous computation response to changing conditions has been found to be a key to competitive advantage for manufacturing firms. In order to cope and reliable communication, are being in the shop-floors and supply to based the whole enterprise. The work Abstract with this, modern firms are entering in thedeployed fourth industrial revolution. Smart piecesinformation of equipment, on ubiquitous computation presented in this paper belong to a pilot project to explore promising technologies in this domain and deploying them in a test-line and reliable communication, are being deployed in the shop-floors and supply information to the whole enterprise. The work Inattoday’s business environment, theintrend towards more product variety and customization is unbroken. Due tointhis development, the need of a large vehicle manufacturer Sweden. Traceability and visibility of assets plays a critical role the process of improving presented in this paper belong to a pilot project to explore promising technologies in this domain and deploying them in a test-line agile and reconfigurable production systems to cope with various products and product families. To design and optimize production shop-floor performance, contributing toemerged better control, planning and scheduling decisions. In detail on the at a large vehicle manufacturer in Sweden. Traceability and visibility of assets plays a critical role inthis the article processfocuses of improving systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to collection of requirement and design of a real-time positioning system for asset tracking including its implementation with shop-floor performance, contributing to better control, planning and scheduling decisions. In detail this article focuses onother the analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and technologies in the company demonstrator. collection of requirement and design of a real-time positioning system for asset tracking including its implementation with other nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production technologies in the company demonstrator. system. new methodology is proposed to analyze existing products in article view ofunder theirthe functional and physical architecture. The aim is to cluster © 2019AThe Authors. Published by Elsevier Ltd. This is an open access CC BY-NC-ND license these products in new assembly oriented product © 2019 The Authors. Published by Elsevier Ltd.families for the optimization of existing assembly lines and the creation of future reconfigurable (http://creativecommons.org/licenses/by-nc-nd/3.0/) © 2019 The Authors. Published by Elsevier Ltd. the Thisphysical is license an open accessofarticle under the BY-NC-ND license This is an open access article under the scientific CC BY-NC-ND (http://creativecommons.org/licenses/by-nc-nd/3.0/) assembly systems. Based on Datum Chain, the products is CC analyzed. Functional subassemblies are identified, and Peer-review under responsibility of Flow the committee ofstructure the 52nd CIRP Conference on Manufacturing Systems. (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on Manufacturing Systems. a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the Peer-review under responsibility of the committee of the to 52nd CIRP Conference on Manufacturing Systems.designers. An illustrative similarity families by scientific providing design support both, production system planners and product Keywords:between real-time product location system; digital twin; Industry 4.0; traceability; industry example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of Keywords: real-time location system; digital twin; Industry 4.0; traceability; industry thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. Introduction ©1.2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.

1.

Introduction The industry for heavy vehicle manufacturing is comes to industrial applications. [4] In the field of CyberKeywords: Assembly; Design method; Family identification challenged by global ongoing changes due to strict Physicalto Systems, distributed[4]intelligent architectures The industry for heavy vehicle manufacturing is comes industrial the applications. In the field of Cyberrequirements for environmental friendly development and define modules which have a reliable connection and share challenged by global ongoing changes due to strict Physical Systems, the distributed intelligent architectures the increase in personal customization of products. These knowledge between each other. One module of requirements for environmental friendly development and define modules which have a reliable connection and share challenges are creating a necessity for companies in the field aforementioned system is the Digital Shadow (DS). [5] A DS increase in personal customization of products. These between each other. manufactured One module of 1.the Introduction of knowledge the product range and characteristics and/or to adapt technologies improving performance, is an advanced virtualization technology, using theAvast challenges are creatingfor a necessity forindustrial companies in the field aforementioned system is the Shadow (DS). [5] DS assembled in this system. In thisDigital context, the main challenge in to Due maintain their fast competitive advantage. [1]performance, The fourthof amount of sensors toismore thesingle real to adapt technologies fordevelopment improving industrial is an advanced virtualization technology, using the vast to the in the domain modelling and analysis now accurately not only torepresent cope with industrial revolution, alsoongoing often advantage. referred as Industry 4.0 world. aOne of the most important stepping stonefamilies, the to maintain their The fourth amount of sensors to more accurately represent theto real communication andcompetitive an trend to of [1] digitization and products, limited product range or existing product was introduced 2013 in Germany. [2] Since then many conceptualization of a fully featured Industry 4.0 application industrial revolution, also often referred are to as Industry 4.0 of to theanalyze most and important stepping stoneto to the digitalization, manufacturing enterprises facing important butworld. also to One be able to compare products define researchers have contributed withenvironments: a common goal,athen tocontinuing specify is product in the development of the Digital Twin The DS was introduced 2013 in Germany. [2] Since many conceptualization fully Industry 4.0 [6] application challenges in today’s market new families.ofItacan befeatured observed that(DT). classical existing and assess possibilities. Cyber-Physical Systems is to one of the is in often seen as starting point ofTwin a DT installation. researchers have contributed a common goal, specify is the development of thein Digital (DT). [6] TheThis DS tendency towards reduction ofwith product development times and product families arethe regrouped function of clients or features. enabling technologies which has gained traction during the concept relies on the specifications that individual installers and assessproduct possibilities. Cyber-Physical of the is oftenassembly seen as the starting point families of a DT are installation. This shortened lifecycles. In addition,Systems there is isanone increasing However, oriented product hardly to find. past years.technologies [3] In similar manner of Things (IoT)the is have received, asthethere is yet tothat beindividual a standard about enabling which hasatInternet gained traction concept relies onfamily specifications installers demand of customization, being the same timeduring in a global On the product level, products differ mainly in two another enabler, however in a different approach when it differences in terminology. The consensus seems to point at past years. [3] In competitors similar manner ThingsThis (IoT) is have received, as(i)there is yet oftocomponents be a standard about competition with all Internet over theofworld. trend, main characteristics: the number and (ii) the anotheris enabler, in a different approach it differences in terminology. The consensus seems to point at which inducinghowever the development from macro when to micro type of components (e.g. mechanical, electrical, electronical). markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly single products 2212-8271 © 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the (http://creativecommons.org/licenses/by-nc-nd/3.0/) 2212-8271 ©under 2019 Theaugmenting Authors. of Published by Elsevier is52nd anable open article under the CC BY-NC-ND license To cope with this ascommittee wellLtd. asThis toaccess product on aSystems. physical level (components level) which Peer-review responsibility thevariety scientific oftothebe CIRP Conference on structure Manufacturing (http://creativecommons.org/licenses/by-nc-nd/3.0/) identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on Manufacturing Systems. production system, it is important to have a precise knowledge comparison of different product families. Addressing this 2212-8271 © 2019 The Authors. Published by Elsevier Ltd. This is an©open article Published under theby CC BY-NC-ND 2212-8271 2017access The Authors. Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-review under responsibility of scientific the scientific committee theCIRP 52ndDesign CIRPConference Conference2018. on Manufacturing Systems. Peer-review under responsibility of the committee of the of 28th 10.1016/j.procir.2019.03.182

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that a DT contains critical control over processes. [7] This creates a distinction between advanced monitoring, the DS implementation and advanced control which are represented by a DT. The bi-directional data flows are the important differentiator. Depending on the specific installation the systems range from needing very complex algorithms and equipment to very simple digital readouts. Following real world installation efforts, to design for and evaluate forthcoming issues, is therefore of high importance.[8] In this paper, an investigation of the requirements from industry is made. The application of the methodology is made as a case study for the manufacturing firm.

possibilities of better control. The concept of Real-Time can be divided into four aspects,

2.

Incorporating these aspects in to the monitoring system creates a complex task, as the data needs to be processed even before it is stored. This needs Real-Time analysis and event processing. The processing should be efficient when looking from the programming perspective, meaning usage of programming code with as small headroom as possible. Striving to reduce latency through every step of the process. Optimizing code is important when dealing with Real-Time flows of valuable information. Data aggregation and transformations need to be at minimal to reduce Central Processing Unit (CPU) overhead. This in turn removes any barriers for the responsiveness of the event. When the changes are noticed faster also the flexibility of the system increases, which may contribute to a higher resource flexibility. Adaptation of future production systems create a need for continuous development and improvement. The future production systems need to change and adapt with the products they are producing.

Background

The firm cooperating in this project has acquired knowledge about the recent trends in the manufacturing and production domain. These trends derive from the recent digitalization possibilities within the fourth industrial revolution. The strive to be a leading partner in the field is very close to the core philosophies that the firm follows, as such the demonstrator is well equipped with modern technologies in 3d printing, robotics and industrial control systems. The number of installations of such demonstrator is increasing in modern firms. [9] They provide a basis to test new technologies and educate employees about new technologies and tools. The technologies in these demonstrators are not seen as a part of a whole, but as individual entities. These systems are yet to be part of a coherent system. The company wishes to implement a responsive and agile monitoring and control system to these systems. By definition creating a DT in the process, as defined above. [10] An example of a DT architecture is the Digital Twin Shop-floor (DTS). [11] In DTS the four main production factors are Equipment, Materials, Environment and Human. Whereas the last factor, the Human, is the most irregular in the chain. Achieving better control over the shopfloor lies therefore on the monitoring aspect of the system. Provided the change from traditional Manufacturing Execution Systems (MES) to a flexible decentralized but yet loosely coupled systems. [12] More Robust, reliable and evaluated system architectures are required. The Line Information System Architecture (LISA) project contributes with an architecture which suits the future of modern firms, allowing for greater expandability while still being easily manageable. [13] The usage of simple yet powerful underlying standards aid in the reusability and incorporation of legacy hardware to modern scalable architectures. The JSON data format is one of the standards which is often relied upon for such tasks. [14] As the industrial revolution is yet to fully flourish, industrial firms may see themselves with equipment not suitable for direct integration with upcoming technologies. A scenario where more often than not the equipment requires machine integrators, translating languages and physical interfaces between two systems. Machine integrators come in different varieties, both physical and digital. [15] The purpose is to quickly, preferably in Real-Time, be able to read and send commands from machine to machine. Faster access to data provides

• • • •

3.

Speed is the measurement of how fast one task is to be finished. Responsiveness is the ability of the system to get back to ready-state, where new commands can be interpreted. Timeliness indicates how the systems is able to handle deadlines and urgency of tasks. Flexibility defines how well the system can adapt to changes in parameters.

Methodology

This work was conducted in cooperation with a heavy vehicle manufacturer in Sweden. A technical test-line was available for application and experimentation of different solutions. The test-line setup can be seen as an advanced demonstrator for disruptive technologies. The demonstrator platform is located in the premises of the firm close to the active production lines. The close proximity to the real implementation creates a better understanding between the needs of the production line and the test-line. The bidirectional data flows lie as ground for the implementation. The research methodology conducted during this

Fig. 1. Bi-directional flow visualization.

experimentation was in great part trial and error backed by extensive history from the firm. Interviews of personnel invested in the projects of the demonstrator were conducted to develop a map of available technologies and how the



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interlinking connections between them could be managed. With the goal finding the requirements for a DT. The firm has an intent of developing an early state of an DT, an exploratory DT of the test-line and its current technologies. The current technologies are categorized as projects and the process of implementation of the technology is conducted as individual tasks. Some projects however, rely on the configuration with other projects. To investigate the task of the concept, analysis of program code was vital to understand the fundamental underlying scripts available by each individual module. Creation and review of Programming code in Java, JavaScript and C# was necessary due to the complex underlying systems. To implement better monitoring of humans and other assets new technologies for traceability are needed. The firm previously conducted a market investigation of suppliers, minimizing the scope of the search for further endeavors. This project has some minor restrictions due to the nature of the task. The demonstrator is located inside secured facilities of the firm which creates limitations with the scope of the applied technologies. This applies especially to the network infrastructure access and free flowing data streams created in different processes. 4.

Findings

The result of the conducted research is an architectural map of the implementation showcasing the additional module placement in the overall system. Each module is described below in the order of engagement to the project. MI/ Smarta IPS Textilier Ergonomic Colours

MI Autonomous Guided Vehicle

PSB

RTLS X, Y, Z

Unity 3D environment

and approved external network entities. The server running the PSB software is located in another department than the test-line, however the firm has implemented a node which sends all data to and from the PSB. This node is based upon the Websocket interface. A solution which efficiently transports the needed data to and from the PSB from the premises of the test-line. The publish and subscribe method of the PSB simplifies the understanding of the different data streams. JSON is mainly used for the messages being sent, creating compatibility with most machines that need to communicate over the PSB. Smart Assembly Tools The smart assembly tools consist of industrial power tools such as wireless screwdrivers. These tools have added modules which allow them to receive and transmit data. The data transmitted contains but is not limited to the torque and speed as well as more advanced functions such as the number of products that have been assembled with that specific screwdriver. On the other spectrum the received data can set specific profiles for the tool as well as limit usage if the product is finished, reducing the risk of time loss from user error. For the function of this module there is a requirement of a MI as the language used by the tools is not conformed with the PSB. Autonomous Guided Vehicle (AGV) The AGV is widely used in many applications of logistics. The AGV at the test-line demonstrator is state of the art with positioning possibilities as well as a mobile app allowing operators to control and monitor the device remotely. With the built-in RGB lights visual indicators can be used for signaling. A competent machine in which many possible technologies can be tested. The AGV uses a data format which conforms to the one of the PSB, however the requirement of a MI is due to the third party application. 3D environment in Unity

WEBSOCKET MI

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Smart Assembly Tools

MI

Fig. 2. The implemented system, yellow marking of created added value.

Plant Service Bus (PSB) The PSB is the core of the architecture that is running the conceptual DT. Derived from aspects of the LISA architecture it provides a rigid base to build upon. The PSB is run on server hardware on the internal system of the firm. To gain access to the system the connected device or devices are required to be either physically be connected to the internal networking of the firm or added to a list of accepted

For the visualization of the DT the firm has chosen the well-known game engine Unity. The choice was made due to the low latency achievable by the engine and the possibility for Multi-User access. The visualization uses different sources to create the correct 3D environment. The usage of drawings of the building, point cloud scans and 3D models of different parts and products. The result is a realistic 3D representation of the real world. A benefit of using a game engine is the possibility of background processing in the software. This gives an opportunity to program some functions and scripts directly in the visualization, reducing the amount of programming needed in the MI. The list of available algorithms can be extensive, encompassing all functions of the device or simply providing the essential commands only. It is also dependent on which programming language used, as the Application Interfaces (APIs) are not available for all as well as some function might be only available for one specific language.

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Most if not all machines are required to be inside the visualization, therefore it is convenient to also use the visualization as the hub of the test-line DT concept. Noted is that any module connected to the PSB can reach and access any other module. This is the benefit of modern distributed architectures. Smart textiles / Ergonomic colours The smart textiles module is the latest technology available. It consists of wearable devices which can sense information from the user. It creates possibilities to know if an operator is using the correct movements during assembly or if the user is experiencing fatigue due to repetitive action. This module requires a MI, however a direct access to the IPS program can be achieved with the correct setup. This module has no need of bi-directional data to the visualization at this date The missing link While the above mentioned modules are integrated in the visualization and are available for monitoring and control, one important aspect is missing in the picture. Asset localization is a vital aspect showcasing where and therefore what is happening to the product at a specific time. In this case the product can be both parts or operators, as knowing where humans are being of great importance to achieve a full implementation of the DT. The technology for tracking assets is called Real-Time Localization System (RTLS) and uses radio frequency (RF) to determine the localization of assets. The firm has chosen one specific supplier for the integration. The supplier requires an installation of stations on the walls, these are stationary modules which are permanent and create the scope of the tracking. After initial calibration one uses beacons which are small portable devices. The position of these beacons can then be tracked with great accuracy in the designated area of the stations. The beacons can be attached to any person or device. Due to the nature of the third party software, a MI is still needed for translation of messages. Infrastructure of the buildings were taken into consideration. Installation of a big amount of sensors in the rooms that needed RTLS can require some planning. Coordinates have to align with 3D environment for all assets. This insinuates the collaboration of all program developers when it comes to the decision of which type of units and where the zero point is. The positioning accuracy should be within the suppliers given specifications. The completed implementation should fit the system design already in place, as well as open for further change if need be. Real-Time Asset Localization and DT The system for asset localization is fully integrated with all other parts of the DT. However due to the third party software security is not optimal. Firewalls create latency issues which are not desirable in the DT. Third party servers creates a barrier if connection are from inside secured

networks, which often is the case when using sensitive data such as localization of humans. Disregarding the teething issues with new technology, the system is now in essence a full conceptual installation of a DT. By attaching the RealTime Asset tracking module, all parts of the DTS are accountable. For example, one could use the localization module with the Smart textiles module to map where and how operators are moving in the wrong way. Another example that is implemented is the cooperation between the human and the AGV, where the AGV can follow the human without the need for external input. 5.

Conclusion

This paper has defined a scenario in which a Digital Twin implementation is viable. By investigating and mapping the already implemented modules, findings of the missing link was made. The Real-Time Asset Localization module is seemingly crucial for the fulfillment of the task. Standardization of the requirements provided a vital role and comes into play when the new technologies quickly need to be implemented and relied upon. Further work with incorporating more modules into the PSB can provide better knowledge about the requirements of a DT installation. Acknowledgement This work was conducted with the help of Lars Hansson, PhD which contributed with direction and clarity on the topic.



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