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Prof Anton Basson, Vice-dean: Teaching
Mechatronics, Automation and Design Research Group
Stellenbosch University
Engineering Faculty
7 June 2019
Digital twins – your systems'
presence in Industry 4.0
Buzzwords
2
Internet of Things
https://www.networkworld.com/article/3234749/7-ways-iot-is-reshaping-the-internet.html
3
The Birth of Internet of Things
htt
ps:
//ta
azaa
.com
/the-t
echnolo
gie
s-th
at-e
nab
le-t
he-
inte
rnet
-of-
thin
gs/
4
Cyber-Physical Systems
• 5-C architecture for CPSs
5
Roy, R
., T
iwar
i, A
., Sta
rk, R
. & L
ee, J
. 2017. P
redic
tive
Big
Dat
a A
nal
ytic
s an
d
Cyb
er
Phys
ical
Sys
tem
s fo
r T
ES
Syst
em
s. P
roce
edin
gs o
f th
e Inst
itution o
f
Mech
anic
al E
ngi
neers
, Par
t B
: Journ
al o
f Engi
neeri
ng
Man
ufa
cture
.
231(1
3):2241–2241.
Cyber-Physical Systems
A C
yb
er-P
hysi
cal
Syst
ems
arch
itec
ture
fo
r In
du
stry
4.0
-
bas
ed m
anu
fact
uri
ng s
yst
ems
Jay L
ee,
Beh
rad
Bag
her
i, H
un
g-A
n K
aoP
ub
lish
ed 2
01
5
DO
I:1
0.1
016
/j.m
fgle
t.20
14.1
2.0
01
6
Big Data
7
Cloud Computing
8
Industry 4.0
Wikipedia
9
Industry 4.0
Ph
ysi
cal
Inte
rnet
– a
No
vel
Ap
pli
cati
on
Are
a fo
r
Ind
ust
ry 4
.0
Inte
rnat
ional
Jo
urn
al o
f E
ng
inee
ring
an
d M
anag
emen
t
Sci
ence
s 4
(1):
152
-16
1
DO
I: 1
0.2
17
91/I
JEM
S.2
01
9.1
.19.
Esz
ter
Pu
skas
, G
ábo
r B
oh
ács
10
Industrie 4.0
11
Cy
ber
-phy
sica
l sy
stem
s in
man
ufa
cturi
ng,
Monost
ori
et
al,
CIR
P A
nnal
s -
Man
ufa
cturi
ng
Tec
hnolo
gy
65 (
2016)
621–641
??
Cyber-Physical Systems
• CPS Maturity Model
12
Cy
ber
-phy
sica
l sy
stem
s in
man
ufa
cturi
ng,
Monost
ori
et
al,
CIR
P A
nnal
s -
Man
ufa
cturi
ng
Tec
hnolo
gy
65 (
2016)
621–641
Cyber-Physical Systems
• Important concepts
13
Cy
ber
-phy
sica
l sy
stem
s in
man
ufa
cturi
ng,
Monost
ori
et
al,
CIR
P A
nnal
s -
Man
ufa
cturi
ng
Tec
hnolo
gy
65 (
2016)
621–641
What is a Digital Twin?
• NASA Definition (adapted)
• Modelling and simulation of the as-built [system] state,
• as-experienced loads and environments, and
• other [system] specific history
to enable
• high-fidelity modelling of individual vehicles
• throughout their service lives
14
Hochhalter, Leser, Newman, Glaessgen, Cornell, Willard & Heber, 2014
What is a Digital Twin?
15
Kritzinger, W., Traar, G., Henjes, J., Sihn, W. & Karner, M. 2018. Digital Twin in manufacturing: A categorical
literature review and classification. IFAC-PapersOnLine . 51(11):1016–1022.
Digital Twins
• General Electric
GE.com
16
Digital Twins
• A Digital Twin to develop Blue Denmark
• Imagine having access to information about every bit of
your ship - from engine performance to hull integrity -
available at a glance throughout the full lifetime of the
vessel
17
What are Digital Twins For?
• Improved planning and dynamic scheduling
• Decrease bottlenecks and resource conflicts
• Improved maintenance
• Using diagnostic and predictive analytics
• Optimization of complex systems
• Simulation using mathematical and statistical models
• Sending control commands to the local microcontrollers
• Real-time sensor data to track effectiveness
• ...
18
What are Digital Twins For?
• ...
• Centralized and integrated data from whole lifecycle
• Differing levels of access, using cloud storage and analytics
• Used for simulation, optimization, design information or
more effective concurrent work of multidisciplinary teams
• Augmented reality technology
• Virtually assisted installation and maintenance
• Worker training
• Reduced energy consumption
• Energy monitoring and forecasting
19
MADRG Digital Twin Research
• Implementation focussed
• Suitable for existing/legacy systems
• Vendor neutral where possible
• Maximum use of "off-the-shelf" software
• Reduced development cost and time
• Cyber-security included
• Human integration
• Augment workers, rather than replace them
• Complex systems' control and coordination
• With provision for future changes/expansions
20
Six Layer Architecture for Digital
Twins
21
Redelin
ghuys
, Bas
son, K
ruge
r, "A
Six
-Lay
er
Arc
hit
ect
ure
for
Dig
ital
Tw
ins
with A
ggre
gation",
acce
pte
d for
SO
HO
MA
2019
Hierarchy of Digital Twins
22
Security
Redelin
ghuys
, Bas
son, K
ruge
r, "A
Six
-Lay
er
Arc
hit
ect
ure
for
Dig
ital
Tw
ins
with A
ggre
gation",
acce
pte
d for
SO
HO
MA
2019
Communication Protocols
23
-<Systems>
-<System Name>
-<Attribute>
<Name>" "</Name>
<OPCID>" "</OPCID>
<DataType>" "</DataType>
<Value>" "</Value>
<ScaleFactor>" "</ScaleFactor>
</Attribute>
</System Name>
</Systems>
Digital Twins in Manufacturing
24
Digital Twin for SA Agulhas
25
Adapted from: Perera, L., Mo, B.: Ship performance and navigation information under high-
dimensional digital models. In: Journal of Marine Science and Technology. 1 – 12 (2019).
Digital Twin for Worker
26
https://www.sonaca.com
https://http://www.aatcomposites.com
Human-Robot Collaboration
27
Digital Twin for Table Grape Farm
28
Digital Twin for Heliostat Field
29
Thank You Dankie Enkosi
http://www.mecheng.sun.ac.za/research-groups-and-centres/groups/
Prof Anton Basson
Dr Karel Kruger
