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A Digital Twin Simulator For R
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)LJXUH Digital twin-based energy saving operation process of discrete manufacturing system
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change RI
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and distribution based on history data.
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feedback to the physical space.
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indicators RI
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and GLJLWDO
DQG digital VSDFH
space DQ
an LPSRUWDQW
important SDUW of GLJLWDO
part RI digital WZLQ
twin. 7KH
The
physical manufacturing system status information of each
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element VKRXOG
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physical
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DIGITAL TWIN SIMULATOR FOR ENERGY SAVING Figure 2. Data structure of digital twin of manufacturing system
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OPERATION OF MANUFACTURING SYSTEM
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the remote monitoring and provide better expansibility for VHQW&RQWLQXHWRUHFHLYHGDWDVHQWE\WKHFOLHQWXQWLOWKH
sent. Continue to receive data sent by the client until the
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the development of digital twin. VLPXODWHGSK\VLFDOV\VWHPUXQWRWKHHQG7KHQWKHVRFNHW
simulated physical system run to the end. Then the socket
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service is terminated.
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the FOLHQW
client, LW
it DOVR
also FUHDWHV
creates WKH
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socket ILUVWO\
firstly, WKHQ
then
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establishes WKH
the VRFNHW
socket FRQQHFWLRQ
connection ZLWK
with WKH
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server. 7KH
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simulated SK\VLFDO
physical V\VWHP
system VWDUWV
starts UXQQLQJ
running. ,Q
In WKH
the UXQQLQJ
running
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process, real-time data are sent to the server continuously.
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the FRQWURO
control LQVWUXFWLRQ
instruction LV
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received, LW
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perform
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6XSSRUW
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the FRUUHVSRQGLQJ
corresponding HQHUJ\VDYLQJ
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immediately. ,IIf QR
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control action is taken. Send the data repeatedly until the
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running RI
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physical V\VWHP
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finished.
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Then the socket connection is disconnected.
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In WKLV
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an H[SHULPHQWDO
experimental FDVH
case LV
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used WR
to
Figure 3. The interactive mechanism between physical and digital space
LOOXVWUDWH WKH SURFHVV RI GLJLWDO WZLQ V\VWHP FRQVWUXFWLRQ
illustrate the process of digital twin system construction
7KH
The VLPXODWHG
simulated SK\VLFDO
physical PDQXIDFWXULQJ
manufacturing V\VWHP
system DQG
and WKH
the HQHUJ\
energy HIILFLHQW
efficient VWUDWHJ\
strategy LQ
in LV
is XVHG
used WR
to UHDOL]H
realize WKH
the
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established in discrete simulation environment is used to HQHUJ\VDYLQJVLPXODWLRQSURFHVV
energy-saving simulation process.
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construct the simulated physical space due to the lack of $ 'HVFULSWLRQRIDGLVFUHWHPDQXIDFWXULQJV\VWHP
A. Description ofa discrete manufacturing system
H[SHULPHQWDO
experimental FRQGLWLRQV
conditions RI
of WKH
the DFWXDO
actual V\VWHP
system. 7KH
The H[DPSOH
example
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interaction flow is shown in Fig.4. The digital space is the
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server and the simulated physical space is the client. $VLPSOLILHGDXWRPRELOHDVVHPEO\OLQHLVXVHGDVDQ
A simplified automobile assembly line is used as an
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experimental FDVH
case >@
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as VKRZQ
shown LQin )LJ
Fig.5. 7KH
The DVVHPEO\
assembly
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OLQH
line is a typical discrete serial manufacturing V\VWHP
LV D W\SLFDO GLVFUHWH VHULDO PDQXIDFWXULQJ system
FRQVLVWLQJ
consisting RI of
6 PDFKLQHV
machines DQG
and
5 EXIIHUV 0% 7KH
buffers (6M5B). The
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parameters of all PDFKLQHVDQGEXIIHUVLQWKHV\VWHPDUH
machines and buffers in the system are
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all JLYHQ
given LQ
in 7DEOH
Table ,I DQG
and ,,
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preliminary VLPXODWLRQ
simulation
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shows that PDFKLQH0LVWKHERWWOHQHFN
machine M4 is the bottleneck PDFKLQHLQWKH
machine in the
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V\VWHP
system.
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The system in simulated physical space
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software 3ODQW
Plant 6LPXODWLRQ
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used WR
to EXLOG
build WKH
the
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discrete manufacturing system model to simulate WKH
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physical V\VWHP
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discrete
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manufacturing system in the physical space is simulated,
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real-time GDWD
data RI
of WKH
the V\VWHP
system LV is FROOHFWHG
collected. 7KHThe GDWD
data
1 FROOHFWHG
collected PDLQO\
mainly LQFOXGH
include PDFKLQH
machine VWDWH PDFKLQH
state (machine
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processing WLPH
time, UHDOWLPH
real-time VWDWH
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allocation RI
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different VWDWHV
states), EXIIHU
buffer VWDWH PD[LPXP FDSDFLW\
state (maximum capacity,
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real-time OHYHO
level), V\VWHP
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indicators (output,
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machine utilization rate, etc.) and energy consumption FRQVXPSWLRQ
1
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indicators (machine energy FRQVXPSWLRQ
consumption). 7KHThe 6LPWDON
Simtalk
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language of Plant Simulation is used for programming to
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obtain real-time data of the system.
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Figure 4. 7KHLQWHUDFWLRQIORZEHWZHHQSK\VLFDODQGGLJLWDOVSDFH
The interaction flow between physical and digital space
&
C. 7KHV\VWHPLQGLJLWDOVSDFH
The system in digital space
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For the server, it creates sockets and then enters the 7KH
The GLJLWDO
digital VSDFH
space LVis HVWDEOLVKHG
established LQ
in 0$7/$%
MATLAB
PRQLWRULQJ
monitoring. $IWHU
After WKH
the FRQQHFWLRQ
connection UHTXHVW
request RI
of WKH
the FOLHQW
client LV
is HQYLURQPHQW)LJVKRZVWKHGLJLWDOWZLQPRGHOEXLOWE\
environment. Fig.7 shows the digital twin model built by
GHWHFWHG
detected, WKH
the VRFNHW
socket FRQQHFWLRQ
connection LV
is HVWDEOLVKHG
established, DQG
and WKH
the 6LP(YHQWVPRGXOHLQ0$7/$%,QWKHGLJLWDOVSDFHWKH
SimEvents module in MATLAB. In the digital space, the
GDWD
data SDFNHWV
packets VHQW
sent E\
by WKH
the FOLHQW
client DUH
are UHFHLYHG
received. %DVHG
Based RQ
on GLJLWDOWZLQPRGHORIWKHH[SHULPHQWDOFDVHLVHVWDEOLVKHG
digital twin model of the experimental case is established
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these data, the system operation state is visually displayed, WR
to UHDOL]H
realize WKH
the YLVXDO
visual UHDOWLPH
real-time PRQLWRULQJ
monitoring RI
of WKH
the V\VWHP
system,
DQG
and WKH
the HQHUJ\
energy VDYLQJ
saving FRQWURO
control VWUDWHJ\
strategy LV
is DGRSWHG
adopted WRto DQG
and WKH
the HQHUJ\VDYLQJ
energy-saving FRQWURO
control PHWKRG
method LV
is UHDOL]HG
realized E\
by
GHWHUPLQHZKHWKHUWKHUHLVDQHQHUJ\VDYLQJRSSRUWXQLW\
determine whether there is an energy saving opportunity. 0$7/$%
MATLAB SURJUDPPLQJ
programming ODQJXDJH
language. 7KH
The HYHQWGULYHQ
event-driven
2QFH
Once LVis DQ
an HQHUJ\
energy VDYLQJ
saving RSSRUWXQLW\
opportunity, WKH
the FRQWURO
control RQOLQHPDFKLQHVWDWHGHFLVLRQEDVHGRQ0D[3OXV$OJHEUD
online machine state decision based on Max-Plus Algebra
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instruction is issued and transmitted to the client. If there LVDGRSWHGIRUHQHUJ\VDYLQJSXUSRVH>@
is adopted for energy saving purpose [11].
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Figure 7. 7KH'LJLWDOWZLQPRGHORI0%VHULDOOLQHEXLOGLQ0$7/$%
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According WRto WKH
the V\VWHP
system GDWD
data WUDQVPLWWHG
transmitted IURP
from WKH
the UHDOWLPH
real-time GDWD
data WUDQVPLWWHG
transmitted IURP
from WKH
the VLPXODWHG
simulated SK\VLFDO
physical
VLPXODWHG
simulated SK\VLFDO
physical VSDFH
space, WKH
the GLJLWDO
digital WZLQ
twin PRGHO
model FDQ
can EH
be VSDFH
space, DIWHU
after HQHUJ\
energy VDYLQJ
saving FRQWURO
control ORJLF
logic DQDO\VLV
analysis, WKH
the
LQLWLDOL]HG
initialized TXLFNO\
quickly, VR
so WKDW
that LW
it FDQ
can EHbe XVHG
used IRU
for UDSLG
rapid FRUUHVSRQGLQJ
corresponding PDFKLQH
machine HQHUJ\
energy VDYLQJ
saving FRQWURO
control LQVWUXFWLRQ
instruction
VLPXODWLRQ
simulation EHIRUH
before WKH
the DFWXDO
actual RSHUDWLRQ
operation RI of WKH
the V\VWHP
system LVRXWSXWDQGIHGEDFNWRWKHVLPXODWHGSK\VLFDOVSDFHLQ
is output and fed back to the simulated physical space in
DFFRUGLQJ
according WRto WKH
the QHHGV
needs RIof XVHUV
users. 5HDOWLPH
Real-time GDWD
data RI
of WKH
the UHDO
real WLPH
time WKURXJK
through LQWHUDFWLYH
interactive WHFKQRORJ\
technology, WRto UHDOL]H
realize WKH
the
V\VWHPWUDQVPLWWHGIURPWKHVLPXODWHGSK\VLFDOVSDFHZLOO
system transmitted from the simulated physical space will HQHUJ\
energy VDYLQJ
saving FRQWURO
control SURFHVV
process. 7DEOH
Table ,,,
III VKRZV
shows WKH
the
EH
be DQDO\]HG
analyzed DQG
and SURFHVVHG
processed LQin WKH
the GLJLWDO
digital VSDFH
space WR
to UHDOL]H
realize HQHUJ\VDYLQJ
energy-saving HIIHFW
effect RI
of WKH
the FDVH
case V\VWHP
system FRPSDULQJ
comparing WKHthe
UHDOWLPHYLVXDOGLVSOD\ZKLFKLVVKRZQLQ)LJ)LJ
real-time visual display which is shown in Fig. 8. Fig.8 (a) D QRHQHUJ\VDYLQJ
no-energy-saving operation scenario (81) DQG
RSHUDWLRQ VFHQDULR 6 and WKH
the
VKRZV
shows WKH
the DFFXPXODWHG
accumulated WLPH
time RIof GLIIHUHQW
different VWDWHV
states RI
of HDFK
each HQHUJ\VDYLQJ
energy-saving RSHUDWLRQ
operation VFHQDULR 6 WKDW
scenario (82) that RQO\
only FRQWUROV
controls
PDFKLQH
machine WKURXJK
through GLIIHUHQW
different FRORUV
colors, LQFOXGLQJ
including SURFHVVLQJ
processing PDFKLQH
machine 0M2. 7KH
The RXWSXW
output ORVV
loss RI
of 6
82 LV
is WKH
the RXWSXW
output ORVV
loss
VWDWH
state, EORFNDJH
blockage VWDWH
state, VWDUYDWLRQ
starvation VWDWH
state, IDLOXUH
failure VWDWH
state DQG
and SHUFHQWDJH
percentage FRPSDULQJ
comparing ZLWK
with 6
81. 7KH
The (QHUJ\
Energy FRVW
cost VDYLQJ
saving
HQHUJ\VDYLQJVWDWH)LJ
energy-saving state. Fig.8 (b) E VKRZVWKHFKDQJHUHDOOHYHO
shows the change real level SHU
per SDUW
part RI
of 6
82 LV
is WKH
the VDYHG
saved HQHUJ\
energy SHU
per SDUW
part SHUFHQWDJH
percentage
RI
of EXIIHU
buffer %
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Fig. F VKRZV
8 (c) shows WKH
the FKDQJH
change VWDWH
state RI
of WKH
the FRPSDULQJZLWK6
comparing with 81.
PDFKLQH0
machine M3.
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9, CONCLUSIONS
VI. &21&/86,216
D. (QHUJ\VDYLQJFRQWUROUHVXOWV
Energy-saving control results
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With the increase of ZRUOGHQHUJ\FRQVXPSWLRQDQG
world energy consumption and
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programming ODQJXDJH
language LV
is XVHG
used WR
to UHDOL]H
realize SHRSOH
people'sV LQFUHDVLQJ
increasing DWWHQWLRQ
attention WR
to WKH
the HDUWK
earth'sV HFRORJLFDO
ecological
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the HQHUJ\
energy HIILFLHQF\
efficiency VWUDWHJ\
strategy LQ
in >@
[11]. $FFRUGLQJ
According WRto WKH
the HQYLURQPHQW
environment, HQHUJ\
energy FRQVHUYDWLRQ
conservation, HPLVVLRQ
emission UHGXFWLRQ
reduction
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and ORZFDUERQ
DQG low-carbon GHYHORSPHQW
development KDYH have EHFRPH
become D a JOREDO
global manufacturing sector," Renewable &6XVWDLQDEOH(QHUJ\5HYLHZV
PDQXIDFWXULQJVHFWRU´5HQHZDEOH Sustainable Energy Reviews,
vol. 81, no.3SS-DQ
YROQR PI, pp. 895-911, Jan. 2018.
consensus. $V
FRQVHQVXV As DQ
an LPSRUWDQW
important SDUW of HQHUJ\
part RI energy FRQVXPSWLRQ
consumption,
[3]
>@ M. *5,(9(6
0 GRIEVES, ³3URGXFW"Product OLIHF\FOH
lifecyc1e PDQDJHPHQW
management: 7KH The QHZ
new
the UHVHDUFK
WKH research RQ on HQHUJ\
energy FRQVHUYDWLRQ
conservation LQ in PDQXIDFWXULQJ
manufacturing paradigm IRU
SDUDGLJP for HQWHUSULVHV´
enterprises," ,QWHUQDWLRQDO
International -RXUQDO
Journal RI of 3URGXFW
Product
industry LV
LQGXVWU\ is RI
of JUHDW
great SUDFWLFDO
practical VLJQLILFDQFH
significance. ,Q
In WKLV
this SDSHU
paper, Development, vol. 2, no. 1/2, pp. 71-84, Jan. 2005.
'HYHORSPHQWYROQRSS-DQ
combined ZLWK
FRPELQHG with WKH
the HPHUJLQJ
emerging GLJLWDO
digital WZLQ
twin WHFKQRORJ\
technology, D a [4]
>@ R. Paolo, "Energy saving by switch-off policy in a pull-controlled
53DROR³(QHUJ\VDYLQJE\VZLWFKRIISROLF\LQDSXOOFRQWUROOHG
production OLQH
SURGXFWLRQ line, 6XVWDLQDEOH
Sustainable 3URGXFWLRQ
Production DQG and &RQVXPSWLRQ´
Consumption,"
digital WZLQ
GLJLWDO twin VLPXODWRU
simulator IRU
for WKH
the HQHUJ\
energy VDYLQJ
saving FRQWURO of
control RI
Sustainable Production and Consumption, vol. 16, pp. 25-32, Oct.
6XVWDLQDEOH3URGXFWLRQDQG&RQVXPSWLRQYROSS2FW
discrete PDQXIDFWXULQJ
GLVFUHWH manufacturing V\VWHP
system LVis HVWDEOLVKHG
established. 7KH
The GLJLWDO
digital 2018.
twin WHFKQRORJ\
WZLQ technology LV is DGRSWHG
adopted WR to UHDOL]H
realize WKH
the UHDOWLPH
real-time [5]
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