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A six-layer architecture for the digital twin: a manufacturing case study implementation

Author

Listed:
  • A. J. H. Redelinghuys

    (Stellenbosch University)

  • A. H. Basson

    (Stellenbosch University)

  • K. Kruger

    (Stellenbosch University)

Abstract

Industry 4.0, cyber-physical production systems (CPPS) and the Internet of Things (IoT) are current focusses in automation and data exchange in manufacturing, arising from the rapid increase in capabilities in information and communication technologies and the ubiquitous internet. A key enabler for the advances promised by CPPSs is the concept of a digital twin, which is the virtual representation of a real-world entity, or the physical twin. An important step towards the success of Industry 4.0 is the establishment of practical reference architectures. This paper presents an architecture for such a digital twin, which enables the exchange of data and information between a remote emulation or simulation and the physical twin. The architecture comprises different layers, including a local data layer, an IoT Gateway layer, cloud-based databases and a layer containing emulations and simulations. The architecture can be implemented in new and legacy production facilities, with a minimal disruption of current installations. This architecture provides a service-based and real-time enabled infrastructure for vertical and horizontal integration. To evaluate the architecture, it was implemented for a small, but typical, physical manufacturing system component.

Suggested Citation

  • A. J. H. Redelinghuys & A. H. Basson & K. Kruger, 2020. "A six-layer architecture for the digital twin: a manufacturing case study implementation," Journal of Intelligent Manufacturing, Springer, vol. 31(6), pages 1383-1402, August.
    • Handle: RePEc:spr:joinma:v:31:y:2020:i:6:d:10.1007_s10845-019-01516-6
    DOI: 10.1007/s10845-019-01516-6
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    References listed on IDEAS

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    1. Adrià Salvador Palau & Maharshi Harshadbhai Dhada & Ajith Kumar Parlikad, 2019. "Multi-agent system architectures for collaborative prognostics," Journal of Intelligent Manufacturing, Springer, vol. 30(8), pages 2999-3013, December.
    2. Jeff Morgan & Garret E. O’Donnell, 2018. "Cyber physical process monitoring systems," Journal of Intelligent Manufacturing, Springer, vol. 29(6), pages 1317-1328, August.
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    Cited by:

    1. Nguyen, Tiep & Duong, Quang Huy & Nguyen, Truong Van & Zhu, You & Zhou, Li, 2022. "Knowledge mapping of digital twin and physical internet in Supply Chain Management: A systematic literature review," International Journal of Production Economics, Elsevier, vol. 244(C).
    2. Vivek Warke & Satish Kumar & Arunkumar Bongale & Ketan Kotecha, 2021. "Sustainable Development of Smart Manufacturing Driven by the Digital Twin Framework: A Statistical Analysis," Sustainability, MDPI, vol. 13(18), pages 1-49, September.
    3. PengYu Wang & Wen-An Yang & YouPeng You, 2023. "A cyber-physical prototype system in augmented reality using RGB-D camera for CNC machining simulation," Journal of Intelligent Manufacturing, Springer, vol. 34(8), pages 3637-3658, December.
    4. Ayman AboElHassan & Soumaya Yacout, 2023. "A digital shadow framework using distributed system concepts," Journal of Intelligent Manufacturing, Springer, vol. 34(8), pages 3579-3598, December.
    5. Hazrathosseini, Arman & Moradi Afrapoli, Ali, 2023. "The advent of digital twins in surface mining: Its time has finally arrived," Resources Policy, Elsevier, vol. 80(C).
    6. Saporiti, Nicolò & Cannas, Violetta Giada & Pozzi, Rossella & Rossi, Tommaso, 2023. "Challenges and countermeasures for digital twin implementation in manufacturing plants: A Delphi study," International Journal of Production Economics, Elsevier, vol. 261(C).
    7. Jyrki Savolainen & Michele Urbani, 2021. "Maintenance optimization for a multi-unit system with digital twin simulation," Journal of Intelligent Manufacturing, Springer, vol. 32(7), pages 1953-1973, October.
    8. Weifei Hu & Jinyi Shao & Qing Jiao & Chuxuan Wang & Jin Cheng & Zhenyu Liu & Jianrong Tan, 2023. "A new differentiable architecture search method for optimizing convolutional neural networks in the digital twin of intelligent robotic grasping," Journal of Intelligent Manufacturing, Springer, vol. 34(7), pages 2943-2961, October.
    9. Maksim Dli & Andrei Puchkov & Valery Meshalkin & Ildar Abdeev & Rail Saitov & Rinat Abdeev, 2020. "Energy and Resource Efficiency in Apatite-Nepheline Ore Waste Processing Using the Digital Twin Approach," Energies, MDPI, vol. 13(21), pages 1-13, November.
    10. Kaishu Xia & Thorsten Wuest & Ramy Harik, 2023. "Automated manufacturability analysis in smart manufacturing systems: a signature mapping method for product-centered digital twins," Journal of Intelligent Manufacturing, Springer, vol. 34(7), pages 3069-3090, October.
    11. Ahmed Ktari & Mohamed El Mansori, 2022. "Digital twin of functional gating system in 3D printed molds for sand casting using a neural network," Journal of Intelligent Manufacturing, Springer, vol. 33(3), pages 897-909, March.
    12. Zander, Bennet & Lange, Kerstin & Haasis, Hans-Dietrich, 2021. "Designing the data supply chain of a smart construction factory," Chapters from the Proceedings of the Hamburg International Conference of Logistics (HICL), in: Kersten, Wolfgang & Ringle, Christian M. & Blecker, Thorsten (ed.), Adapting to the Future: How Digitalization Shapes Sustainable Logistics and Resilient Supply Chain Management. Proceedings of the Hamburg Internationa, volume 31, pages 41-62, Hamburg University of Technology (TUHH), Institute of Business Logistics and General Management.
    13. Chi Ma & Hongquan Gui & Jialan Liu, 2023. "Self learning-empowered thermal error control method of precision machine tools based on digital twin," Journal of Intelligent Manufacturing, Springer, vol. 34(2), pages 695-717, February.
    14. Hassan Alimam & Giovanni Mazzuto & Marco Ortenzi & Filippo Emanuele Ciarapica & Maurizio Bevilacqua, 2023. "Intelligent Retrofitting Paradigm for Conventional Machines towards the Digital Triplet Hierarchy," Sustainability, MDPI, vol. 15(2), pages 1-30, January.

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