Automated Generation of Simulation Models and a Digital Twin Framework for Modular Production

This study presents the development of a Digital Twin (DT) framework that is capable of generating and adjusting simulation models of production processes and systems automatically and in real-time. A Machine Vision (MV) system is used to detect newly added or already existing production module locations and rotations, as well as changes in both their location and rotations. This subsystem primarily functions as an External database and is used for new Asset Administrative Shell (AAS) creation, housing, and data gathering, which also includes a visualization platform. Tecnomatix Plant Simulation (TPS) is used for simulation model building, simulation execution, and high-level scheduling based on work orders and technological plans. Different subsystems were integrated into the DT framework using fast and reliable communication protocols. The automation of the proposed framework significantly reduces manual intervention, thus eliminating human factors, reducing the time needed for model creation, improving simulation fidelity, and providing the fundamentals for robust connectivity within the DT framework. The findings highlight the transformative potential of this method for streamlining simulation processes and enhancing system adaptability in complex environments.