Remote Manufacturing Equipment Control Using Digital Twin and Mobile Robots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems for controlling manufacturing equipment require manual human intervention when problems arise, leading to delays, suboptimal solutions, and increased costs due to the need for on-site experts, which can slow down the manufacturing process.
Innovation Solution
A system comprising a mobile robot, monitoring devices, and computing equipment that allows remote control and simulation of manufacturing equipment operations, enabling remote problem-solving and solution validation before implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual human experts are deployed to solve problems on-site, then the problem can be solved with human judgment and adaptability, but the manufacturing process is delayed due to travel time and the costs increase
Solution Approach 1:
The system creates a digital twin (virtual copy) of the manufacturing equipment that replicates its physical state and behavior. This digital representation allows remote experts to interact with and diagnose problems on the virtual model, eliminating the need for physical travel while maintaining accurate problem-solving capability. The digital twin serves as a faithful copy that preserves all relevant operational data and characteristics.
Solution Approach 2:
The system introduces a communication system as an intermediary between the remote expert and the physical equipment. This intermediary transmits real-time operational data, sensor readings, and control signals, enabling the expert to remotely observe and control the equipment without being physically present. The intermediary bridge eliminates travel time while maintaining the expert's ability to solve problems effectively.
2Ease of operation
If human experts travel to the equipment location, then they can directly observe and manipulate the equipment, but the solution process becomes slow and the manufacturing downtime increases
Solution Approach 1:
The system replaces the mechanical presence of human experts with automated control systems and digital interfaces. Remote experts interact with virtual representations and send automated control signals, eliminating the need for physical travel and manual manipulation. This substitution maintains the ability to observe and control equipment while dramatically reducing response time and preventing manufacturing delays.
Solution Approach 2:
The system performs preliminary actions by continuously collecting and processing operational data, pre-configuring diagnostic tools, and preparing control sequences before problems occur. When issues arise, the remote expert can immediately access pre-processed information and implement pre-planned solutions, eliminating the time required for on-site assessment and preparation that would delay manufacturing.
3Loss of time
If remote control is implemented without digital representation, then the response time is reduced, but the ability to accurately diagnose and test solutions is compromised
Solution Approach 1:
The digital twin serves as a precise virtual copy that replicates the physical equipment's state, behavior, and operational characteristics. This accurate copy enables remote experts to diagnose problems with the same precision as on-site observation by providing real-time data, sensor readings, and operational parameters. The fidelity of the digital representation ensures that remote diagnosis accuracy matches or exceeds physical inspection.
Solution Approach 2:
The system continuously pre-processes operational data, maintains real-time synchronization with the physical equipment, and prepares diagnostic information before problems occur. This preliminary data collection and processing ensures that when issues arise, the remote expert immediately receives accurate, pre-analyzed information, maintaining diagnostic precision while enabling instant response without physical presence.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
System for remote control of an operation of manufacturing equipment (5), the system comprising: at least one mobile robot; at least one monitoring device (2); computing equipment (4) configured to: receive an input from the at least one monitoring device (2) concerning the operation of the manufacturing equipment (5); create a digital representation of the operation of the manufacturing equipment (5); in an event of a problem in the operation of the manufacturing equipment (5), detect the event and create a notification; provide the notification to a user (6); receive an input from the user (6), and enable the user (6) to interact with the digital representation such that the user (6) can identify a solution to the problem, said solution comprising an intervention of the at least one mobile robot (3); control the at least one mobile robot (3) for implementing the solution. Also, a method.