Question: 4. Conclusions By integrating into the current flexible production systems, the components and technologies of Industry 4.0, collaborative robots, intelligent machines, additive manufacturing, Digital Twins,
4. Conclusions
By integrating into the current flexible production systems, the components and technologies of Industry 4.0, collaborative robots, intelligent machines, additive manufacturing, Digital Twins, and simulation, a new qualitative leap can be made towards the mass customization of products at the request of customers. The direction of applied research on the integration of flexible production systems in Industry 4.0 is part of the current concerns at the international level and is associated with upward development in multinational companies in the country and has allowed the achievement of important results of an applicative nature. Through the analysis of the Digital Twin (DT) concept, a leading simulation concept for Industry 4.0, its applications in the industrial environment could be identified. This resulted in the possibility of applying DT starting from the design, dimensioning, and configuration stages of the system, all the way through to its implementation, commissioning, and operation. Production processes and operational efficiency have been optimized, and new opportunities have emerged for integration into the evolving paradigm of Industry 5.0. A novel element of this research is the realization of the Digital Twin of the analyzed Flexible Manufacturing System, using the Process Simulate software package from Tecnomatix/Siemens, version 15.1.2 [89], in a manufacturing company. An important step has been taken in human resources by training operators to acquire new skills in working with collaborative robots and human-machine interaction (HMI Concept), thus preparing the company for the transition to Industry 5.0.
Research in the field of implementing a "Digital Twin" in the manufacturing process began by digitizing the experimental system, obtaining results regarding the following:
- Proposing solutions to optimize the process through digitization using Industry 4.0-specific technologies with implications for production and management;
- The implementation of collaborative robots, simulation studies on interactions with the human operator (HMIhuman-machine interface), and ergonomic studies;
- The implementation of the AGVS (automated guided vehicle system) concept.
The applied scientific research was carried out through concrete activities, with the final result being the software design of the digital copy: defining devices and equipment based on the experimental physical model and the kinematic realization; defining the sensors; performing time-based simulation; identifying mechanical interactions between equipment and highlighting potential collisions; the optimization solution for avoiding collisions by analyzing several scenarios; realizing the simulation based on discrete events, in which the event sequences validate both the equipment from a constructive point of view and the operation logic of the process; and utilizing the optimization solution by implementing complex, robot-type equipment, where many interactions occur simultaneously.
Expanding the research by disseminating the results and applying the studied concepts and designed models within a manufacturing company, through a scientific research contract, was an immediate priority. A future research direction resulting from the current study is the virtual commissioning of the existing physical experimental system by implementing the new virtual commissioning concept. The result will be an extended model that can be applied in a real factory, allowing for the detection of any anomalies in operation before connecting to any real equipment, as well as the reduction of physical commissioning time, with favorable implications in production management. Further developments were proposed for the short term, through other studies and implementations in several companies based on specific case studies. This research contributes to a technical advance and evolution in the way production systems interact with their economic and social environment, promoting interconnectivity and adaptability in a more applied way.
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