Line level digital twin

Optimising efficiency with real-time digital simulation

Project: R3GROUP

Publisher: Fill

Technology: Digital Twin

Industry: Manufacturing

INTRODUCTION

The Line Level Digital Twin is a dynamic simulation model designed for manufacturing firms. It provides real-time insights and decision-making support to optimize production lines, enhance efficiency, and reduce operational costs.

The system enables complex case integration, adapting to market demands through advanced digital tools like Material Flow Simulation, Virtual Commissioning, and Augmented Reality.

This solution improves resource optimization, including energy and material consumption, while enhancing communication with clients through transparent processes.

The Line Level Digital Twin is perfect for manufacturing firms, specifically mechanical engineers and innovation
departments seeking to reduce CAPEX, improve effectiveness, and streamline production processes.

FEATURES/BENEFITS

The main benefits of this solution are: 

  • Reduce CAPEX by optimising production planning.
  • Improve raw material consumption and enhance product quality.
  • Cost-effective alternative to commercial FEA tools.
  • Generation of formability report along with visual representation of problematic features.


TECHNICAL INFORMATION

The Line Level Digital Twin solution stands out by enabling complex case integration and adaptation to rapidly changing market demands. The base level is a virtual image of the pilot line, often called a virtual factory, which is a detailed digital replica of a real factory. This layer is used to determine which tool from the established toolbox (Material Flow Simulation, Virtual Commissioning, Augmented Reality) is best suited for the efficient optimization of the pilot line in terms of their specific needs. This covers the handling of resources including the optimization of the overall energy consumption - a feat not readily achievable with standard modular quality controls.

RESOURCES

USE CASE

Top Layer: Virtual Representation of Pilot Line (photos at the bottom of the page)

This layer is used to determine which tool from the toolbox is best suited for the pilot line. The base level is a virtual imagen of the pilot line, often call a virtual factory, which is a detailed digital replica of a real factory. This replica includes the machines and operations in a 2D or 3D graphic. This digital copy is an accurate representation of the real object and is continuously updated. This layer is used to predict the future behaviour and performance of built systems.

 

USE CASE 1 - Tool A: Material flow simulation

Process simulation is suitable for Pilot Lines, where the focus is on the configuration of subunits and their overall interaction in a feasible way. This tool allows to simulate the reconfiguration of processes, machine positions and robots leading to early validation of machine concepts through error minimization and optimization in the design and development phase. Furthermore, the decoupled software development is independent of the machine development and allows for the simulation of various scenarios and operating conditions without risking the real system.

USE CASE 2 - Tool B: Virtual Commissioning (VIBN)

VIBN is a process where planning data is loaded, tested, and modified on a virtual machine before the programs are transferred to the real machine of the Pilot Lines. This tool can simulate the whole drives of the software and returns the position to the plc or robotic software. Hence, every signal of the machines is considered and therefore advances the reconfigurability in view of programming of the plc and robot via the OPC UA (Open Platform Communications Unified Architecture) standard. OPC UA enables seamless interoperability across different manufacturers, operating systems, and communication protocols and supports the industrial Internet of Things (IIoT) by facilitating information exchange between enterprise systems and real-world devices.

USE CASE 3 - Tool C: Augmented reality

The prior visualisation of the planned system (Pilot Line) as it is often not easy to envision (how the finished system will look in the customer's shopfloor) and whether the space can be used in the best possible way. Support is provided by the use and assistance of augmented reality (AR). Here an overlay of the simulated machine with the real environment can be achieved, helping the user to integrate it as faithfully as possible to the real image in its environment via a Hololens. The Hololens can visualize the Simulation in Augumented Reality to check if the machine can fit into certain areas. Easy applicable to adjustments and re-evaluation of the Pilot Line.

 

SERVICES LINKED

PUBLISHERS