Process monitoring and optimization based on digital twin and virtual reality

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Πετρούλιας, Σταμάτιος
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Over the last decades, the digitalization of manufacturing processes and manufacturing systems has enabled engineers to collect data regarding machining operation. Based on the utilization of such data, in conjunction with the development of suitable frameworks, for data acquisition, data fusion, and data processing, it has become feasible to acquire a data-based estimation of the machine and the process status. By extension, the utilization of the datasets derived from the monitoring lay has involved the foundation for controlling the machine operation and the machining process execution parameters, to the engineers. Further to that, process monitoring based on the implementation of sensing systems can facilitate the control of ultra-precision machining. Therefore, the conventional manufacturing paradigm is transforming into the so-called Digital Manufacturing. It is stressed that this transformation is highly driven by the ongoing developments of Industry 4.0. In addition to that, cutting-edge digital technologies, such as Extended Reality (XR) (Augmented Reality – AR, Mixed Reality – MR, Virtual Reality – VR) are constantly being integrated into modern manufacturing systems, to visualize processes, gain access to data, and optimize processes. The technology of Digital Twin gains more and more space in the industrial domain, as it enables a digital interface between the user and the digital representation of the machine. As a result, time and costs are minimized basically during the maintenance and production phases. So, the scope of this thesis is the design and development of a digital desktop manufacturing cell consisting of a 3D Printer and a Robot, in Unity Game Engine. As for the monitoring, Virtual Reality Oculus Rift headset will be utilized. Through the integration of the aforementioned state of the art technologies, and the use of simulation, training courses and improvements on the manufacturing plant can be performed.
Industry 4.0, Mixed reality