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The cyber-physical data of equipment whole life cycle are interrelated and play an important role in decision-making for business activities. However, multi-stage cyber-physical data are numerous, heterogeneous, and massive; non-real-time information data and real-time physical data are challenging to correspond to each other because of the inconsistency in space-time and granularity. As a result, equipment multi-stage heterogeneous cyber-physical data are difficult to effectively integrate and apply. Therefore, multi-stage cyber-physical data fusion of equipment is a key problem to be solved in manufacturing. To the best of our knowledge, a practicable framework and method to effectively fuse and apply equipment multi-stage data are still missing. To overcome this gap, this study proposes a multidimensional and multilevel cyber-physical fusion method for equipment. First, a four-dimensional cyber-physical fusion framework based on time, data, model, and structure is put forward. Then, the four kinds of fusion, including data fusion, model fusion, knowledge fusion, and digital twin (DT) application fusion, are discussed detailedly. Besides, the five types of algorithms set to support the fusion process are given. Finally, equipment life cycle activity is regarded as a DT application process using dynamic association of data and models. Through cyber-physical fusion, the data of equipment multi- stages could be applied for different activities to solve problems by means of DT. As a primary verification of the feasibility of the proposed approach, a case study of metro vehicle performance evaluation has been carried out, and the results have well confirmed that the multi-stage cyber-physical fusion method is feasible. [ABSTRACT FROM AUTHOR]

With the increasing dynamic nature of customer demand, production, product, and manufacturing design changes have become more frequent. Moreover, inadequate validation during the manufacturing design phase may result in additional issues, such as process redesign and layout reallocation, during the operation phase. Therefore, systems that can pre-validate and allow accurate and reliable analysis in the manufacturing design phase, as well as apply and optimize variations in production lines in real time, are required. Previously, digital twin (DT) has been studied a lot in product design and facility prognostics and management fields. Research on the system framework leading to DT utilization and optimization and analysis through DT in complex manufacturing systems with continuous processes such as production lines is insufficient. In this study, a system based on a DT and simulation results is developed; this system can reflect, analyze, and optimize dynamic changes in the design of processes and production lines in real time. First, the framework and application of the proposed system are designed. Subsequently, optimization methodologies based on heuristics and reinforcement learning (RL) are developed. Finally, the effectiveness and applicability of the proposed system are verified by implementing an actual DT application at a real manufacturing site. [ABSTRACT FROM AUTHOR]

Subject of Research. The paper analyzes the current concept of digital twins in relation to production systems. The review is given for characteristics and parameters of the digital twin that create advantages of using this concept for production systems at their life cycle stages. Technical implementation variants for the concept of digital twins are proposed aimed at improvement of the technological processes of production systems at the following stages of the life cycle: an idea, project, realization, operation, and disposal. Method. We performed a retrospective analysis of scientific papers on the methodology and practical application of software-based approaches to the design, implementation and operation of industrial systems in Industry 4.0. An expert assessment and applicability analysis of the digital twins at the stages of the life cycle of production systems are given. Main Results. The main characteristics of the digital twin affecting the effectiveness of the concept application in production systems are determined and arranged into groups according to their importance based on the analysis of the foreign studies over the past 10 years. The advantages and disadvantages of a software-oriented approach application to the design, implementation and operation of production systems are formulated. Practical Relevance. The digital twin characteristics are determined that affect the efficiency of its usage at the life cycle stages of production systems. Variants of the modern concept technical implementation of digital twins for production systems are proposed by applying of advanced digital technologies and intelligent electronic devices. Requirements are systematized concerning functionality, performance, correspondence accuracy of the virtual and physical environment state, as well as the qualitative characteristics of the digital twin. They provide for the assessment about the applicability of digital twins for solving existing problems of control and management in production systems.

With the increasing dynamic nature of customer demand, production, product, and manufacturing design changes have become more frequent. Moreover, inadequate validation during the manufacturing design phase may result in additional issues, such as process redesign and layout reallocation, during the operation phase. Therefore, systems that can pre-validate and allow accurate and reliable analysis in the manufacturing design phase, as well as apply and optimize variations in production lines in real time, are required. Previously, digital twin (DT) has been studied a lot in product design and facility prognostics and management fields. Research on the system framework leading to DT utilization and optimization and analysis through DT in complex manufacturing systems with continuous processes such as production lines is insufficient. In this study, a system based on a DT and simulation results is developed; this system can reflect, analyze, and optimize dynamic changes in the design of processes and production lines in real time. First, the framework and application of the proposed system are designed. Subsequently, optimization methodologies based on heuristics and reinforcement learning (RL) are developed. Finally, the effectiveness and applicability of the proposed system are verified by implementing an actual DT application at a real manufacturing site.