<p>The use of new digital tools has been increasing in the creation of intelligent manufacturing systems. These new tools make possible the development of complex mechatronic systems through their entire life cycle. During virtual design and mechatronic system conceptualization, there is a need to integrate mechanical, electrical, electronic, control, and electro-mechanics concepts among others to create a proof of concepts for the complex systems. Digital twins design and analysis connects virtual and physical prototypes validating the performance of the complex mechatronic systems. In recent years, several researchers have been exploring different engineering aspects using advanced tools related to Computer Aided Design (CAD), Computer Aided Engineering (CAE), and Computer Aided Manufacturing (CAM) for complex mechanical components and their assembly. Other researchers have deemed these efforts as CAD/CAE/CAM research analysis in the Computer Integrated Manufacturing (CIM) domain. Different engineering characteristics such as stress, strain, thermal, vibration, and electromagnetism have been widely explored by researchers to make better mechanical design, analyze different materials, and to implement advanced CAD/CAE/CAM approaches. However, intelligent automation system development requires not only the integration of the engineering concepts mentioned at component level, but also the combination of these concepts to make possible the creation of digital twins and to analyze virtually the entirety of manufacturing systems. This is a reason why the digital tools and new CAD/CAE/CAM approaches for intelligent mechatronic systems need to be expanded. The motivation for this research is to explore new methods, technologies, and tools to aid in the creation of digital twins using an intelligent conveyor system as case study. Industry 4.0 is considered the next industrial revolution combining new manufacturing paradigms such as Digital Twins, IIoT, CM and ML in the creation of intelligent manufacturing systems. The main aim of this paper is to propose a new approach in developing intelligent manufacturing systems by using virtual tools and implementing IIoT, CM and ML technologies. The new approach explores a Next Generation Industrial Transport Technology and virtual tools by B&amp;R Industrial Automation. For example, a B&amp;R SuperTrak system is virtually designed and analyzed representing the digital twin concept. For this SuperTrak system, it was identified the mechanical, electrical, electronic, control, and electro-mechanics aspects of the system allow for the new transport technology to work using the digital twin concept. Important emphasis is focused on how a Programmable Logic Controller (PLC) and Human Machine Interface (HMI) can manipulate the SuperTrak functionality by connecting the physical and virtual prototype of a small conveyor section. This research explores how the different instruments and controls on the SuperTrak are connected to the PLC and HMI to make possible the new conveyor system functionality. In the conceptualization of the new conveyor, it is important to analyze how the different SuperTrak pallets are moving in the conveyor system, such as the individual speeds and accelerations of each pallet based on the programming environment. Important research is conducted on how B&amp;R implements IIoT aspects communicating to the sensors installed on the SuperTrak and how the inputs and outputs are connected to the PLC and HMI using the IIoT technologies. Cloud Manufacturing is an important concept, and it is explored how one sensor variable is stored in the cloud before being analyzed by the PLC. For example, the position of the SuperTrak pallet within the conveyor system. The Machine learning aspect is as well an important component, and it is explored how a simple algorithm can be used to analyze the position variable behavior of the pallet to make better the SuperTrak system’s functionality. The research novelty contribution is not only presenting a new approach to design a B&amp;R SuperTrak digital twin, but also implementing IIoT, CM and ML technologies in the creation of better intelligent mechatronics systems.</p>

A New Approach to Develop an Intelligent Manufacturing System Using Virtual Tools

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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