Design and development of a hybrid cell digital twin for process control optimization
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Date
2025-03-07
Authors
Βέργαδος, Χρήστος
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Abstract
This diploma thesis addresses the issue of digital twin of a hybrid cell in manufacturing. In the current highly competitive business environment and the increasing demand for personalized products, the necessity of investigating potential system alternatives towards a more efficient manufacturing system design arises more intensely than ever. In an era of economic uncertainty and increased awareness for the ecosystem, sustainability is and will be a crucial issue that will influence many aspects in the industry. To overcome the challenges of waste, high operating costs, and deviations in production, enterprises have begun to transition their production practices to Industry 4.0, also referred to as the Fourth Industrial Revolution, that has emerged in the present-day period. One of the concepts that Industry 4.0 has brought to surface is the Digital Twin. The digital twin, as a virtual representation of a physical object or system, can transfer real-time data on the production process, enabling predictive capabilities to increase productivity, resulting in improved decision-making, risk mitigation, and efficient resource allocation. This thesis proposes a novel design for a hybrid cell digital twin focused on optimizing additive manufacturing and milling processes. Hybrid cells provide flexibility, reduced lead times and can create personalized products in smaller batches. The research methodology starts with creating a 3D model to simulate the physical system in software. Subsequently, communication protocols will be employed to interoperate the physical and digital systems to collect and fuse data to be used to optimize production in the hybrid cell.
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Keywords
Hybrid cells, Digital twin, Optimization, Industry 4.0, Manufacturing