This paper presents a comprehensive study on the implementation of real-time digital twins for industrial cobots, with a focus on the ABB GoFa CRB 15000 cobot. It highlights the relevance of digital twins in the context of Industry 4.0 and their ability to improve operational efficiency by representing physical processes in virtual models. The project's primary objective is to develop a real-time digital twin system to develop the bidirectional monitoring and control of industrial cobots, particularly in assembly tasks. This paper addresses the challenges encountered and the proposed solution, which include offline and online programming, the adoption of the OPC UA protocol for communication, and the use of ABB RobotStudio for simulation. A framework for understanding the implementation is provided, followed by a detailed analysis of the results obtained, as well as discussion and conclusions. An exploration of possible future work is also included, providing a comprehensive view of the project and its importance in the field of industrial robotics and digital twin technology.

For manufacturers of complex interdisciplinary system solutions, the Digital Thread is an essential element that serves as the backbone of technical and organizational data flows. This study proposes a graph-based Digital Thread that integrates a Digital Model and a derived Digital Twin in a native graph database in a polyglot architecture. The approach includes dynamic processes such as advanced interdisciplinary change management and additional data from different lifecycle phases, using objects and relations described by attributes to minimize redundancy while enabling view creation and filtering. Companies often have discipline-oriented IT landscapes that create data silos and prevent contextbased integration of data and process models. The Digital Thread as a backbone represents an approach to overcome these silos as a system lifecycle-spanning system.

Die Nutzung von Augmented Reality (AR) stellt eine Vielzahl von Lösungsansätzen für Herausforderungen unterschiedlicher Bereiche, z.B. der Industrie, Medizin, Unterhaltungsmedien und Bildung, zur Verfügung. Speziell werden hier die Möglichkeiten von AR in der Fertigungsindustrie, genauer bei der Abnahme elektrischer Antriebe der Siemens AG, betrachtet. Dabei werden unter anderem messbare Größen wie Drehmoment, Ankerstrom, -spannung, Drehzahl, Schwingungen, Fertigungstoleranzen etc. gemessen, aber auch nicht quantifizierbare Größen wie Sichtprüfungen von Schweißnähten und Lackierung in Betracht gezogen. Angestrebt wird eine Methode, welche es zukünftig ermöglicht, die Inbetriebnahme ortsunabhängig zu verfolgen und Inspektionen aus der Ferne durchzuführen. Die Herausforderung liegt dabei darin, eine zumindest gleichwertige, wenn nicht sogar verbesserte Erfahrung und Prüfergebnisvalidität für die Beteiligten gegenüber der vor Ort Abnahme zu erzeugen. Im Rahmen des Forschungsvorhabens wurde in interdisziplinärer Zusammenarbeit zwischen Ingenieur/-innen und Sozialwissenschaftler/-innen ein Demonstrator-Konzept für eine ortsunabhängige Maschinenabnahme entwickelt.

The Master’s thesis deals with design of digital twins of machine tools and application of designed procedure on a case study – digital twin of the machine tool MCV 754 Quick. In the first part are described current roles of digital twins in the field of machine tools and also hardware and software options for creating them. Software and hardware tools by Siemens (Mechatronics Concept Designer and SIMIT) are used for the case study. The complex procedure of creating the digital twin is designed in the second part, starting with preparation of a model, ending with the virtual commissioning of the machine tool MCV 754 Quick. The procedure is described in detail, including preparation of 3D model of the machine tool, assignment of physical properties and joints, preparation of PLC, connection all the elements of the whole system: Sinumerik – SIMIT – Mechatronics Concept Designer and controlling the twin via CNC automation system. Output of the thesis is the virtually commissioned machine tool, capable of being controlled by Sinumerik 840D sl. This is the first step in development of the full-fledged digital twin of machine tool, which can be used for testing the functionality and capability of this new technology in industry.

Den här rapporten behandlar ett projekt utfört i kandidatkursen TDDD96 - Kandidatprojekt i programvaruutveckling. Projektet är utfört av åtta studenter från datateknik- ochmjukvaruteknikprogrammen på Linköpings universitet (LiU) för kunden från institutionen för medicinsk teknik (IMT) på LiU. Syftet med projektet var att ta fram en prototypmed ett grafiskt gränssnitt för uppvisning och simulering av hur kroppen påverkas av t.ex.träning, sömn och kostintag. Modellerna som simulerats är framtagna av forskningsgrup-pen integrativ system biologi för institutionen för medicinsk teknik LiU och resultatet är i form av dataändringar och grafer i programmets gränssnit.

Digital twins for industrial control systems have gained significant interest over recent years. This attention is mainly because of the advanced capabilities offered by digital twins in the areas of simulation, optimization, and predictive maintenance. Some recent studies discuss the possibility of using digital twins for intrusion detection in industrial control systems. To this end, this thesis aims to propose a security framework for industrial control systems including its digital twin for security monitoring and a machine learning-based intrusion detection system for real-time intrusion detection. The digital twin solution used in this study is a standalone simulation of an industrial filling plant available as open-source. After thoroughly evaluating the implementation aspects of the existing knowledge-driven open-source digital twin solutions of industrial control systems, this solution is chosen. The cybersecurity analysis approach utilizes this digital twin to model and execute different realistic process-aware attack scenarios and generate a training dataset reflecting the process measurements under normal operations and attack scenarios. A total of 23 attack scenarios are modelled and executed in the digital twin and these scenarios belong to four different attack types, naming command injection, network DoS, calculated measurement injection, and naive measurement injection. Furthermore, the proposed framework also includes a machine learning-based intrusion detection system. This intrusion detection system is designed in two stages. The first stage involves an offline evaluation of the performance of eight different supervised machine learning algorithms on the labelled dataset. In the second stage, a stacked ensemble classifier model that combines the best performing supervised algorithms on different training dataset labels is modelled as the final machine learning model. This stacked ensemble model is trained offline using the labelled dataset and then used for classifying the incoming data samples from the digital twin during the live operation of the system. The results show that the designed intrusion detection system is capable of detecting and classifying intrusions in near real-time (0.1 seconds). The practicality and benefits of the proposed digital twin-based security framework are also discussed in this work. / Digitala tvillingar för industriella styrsystem har fått ett betydande intresse under de senaste åren. Denna uppmärksamhet beror främst på de avancerade möjligheter som digitala tvillingar erbjuder inom simulering, optimering och förutsägbart underhåll. Några färska studier diskuterar möjligheten att använda digitala tvillingar för intrångsdetektering i industriella styrsystem. För detta ändamål syftar denna avhandling till att föreslå ett säkerhetsramverk för industriella styrsystem inklusive dess digitala tvilling för säkerhetsövervakning och ett maskininlärningsbaserat intrångsdetekteringssystem för intrångsdetektering i realtid. Den digitala tvillinglösningen som används i denna studie är en fristående simulering av en industriell fyllningsanläggning som finns tillgänglig som öppen källkod. Efter noggrann utvärdering av implementeringsaspekterna för de befintliga kunskapsdrivna digitala tvillinglösningarna med öppen källkod för industriella styrsystem, väljs denna lösning. Cybersäkerhetsanalysmetoden använder denna digitala tvilling för att modellera och exekvera olika realistiska processmedvetna attackscenarier och generera en utbildningsdataset som återspeglar processmätningarna under normala operationer och attackscenarier. Totalt 23 angreppsscenarier modelleras och utförs i den digitala tvillingen och dessa scenarier tillhör fyra olika angreppstyper, namnskommandoinjektion, nätverks -DoS, beräknad mätinjektion och naiv mätinjektion. Dessutom innehåller det föreslagna ramverket också ett maskininlärningsbaserat system för intrångsdetektering. Detta intrångsdetekteringssystem är utformat i två steg. Det första steget innebär en offline -utvärdering av prestanda för åtta olika algoritmer för maskininlärning övervakad på den märkta datauppsättningen. I det andra steget modelleras en staplad ensemble -klassificerarmodell som kombinerar de bäst presterande övervakade algoritmerna på olika etiketter för utbildningsdataset som den slutliga modellen för maskininlärning. Denna staplade ensemblemodell tränas offline med hjälp av den märkta datauppsättningen och används sedan för att klassificera inkommande dataprover från den digitala tvillingen under systemets levande drift. Resultaten visar att det konstruerade intrångsdetekteringssystemet kan upptäcka och klassificera intrång i nära realtid (0,1 sekunder). Det praktiska och fördelarna med den föreslagna digitala tvillingbaserade säkerhetsramen diskuteras också i detta arbete.

Virtualization of products means the representation of some of their properties by models. In a stronger digitalized world, these models will gain a much broader use than models had in engineering so far. Even for one modelling aspect different models of the same product will be used, depending on the specific need of the model user. That need may change in the course of product life, between first product concepts till over the different phases of development, to product use, maintenance, or even recycling. Since a digitalized world use of these diverse models will not be limited to experts model consistency will play a much stronger role. Model hierarchies will play a stronger role and can serve also as means for teaching product users a deeper understanding of product properties. A consistent model hierarchy leading from a simple to a more advanced property representation can support this learning process. In this paper perturbation methods are analyzed as a means for setting up model hierarchies in a consistent manner. This is studied by models for the behavior of a electrohydraulic drive, which consists of a variable speed motor, a pump, a double stroke cylinder and a counterbalance valve. Model hierarchy is achieved by model reduction in the sense of perturbation theory. The use of these different models for different questions in a system design context and their interrelations are exemplified.

Over the last few decades, the complexity and variety of automation systems have increased dramatically. Commissioning has grown more and more critical for the entire industry. Conventional commissioning is time-consuming and expensive. It's always been a challenge in manufacturing to put new designs into production or implement new technologies, control codes, or tactics. In Virtual Commissioning (VC), control programs of the physical system's Digital Twin (DT) can be validated in Software-in-the-Loop (SIL) before the actual commissioning. The emergence of new VC tools and methods has become a tremendous advantage, bringing the values of shorter duration, flexibility, and lower risks to the commissioning process. In this thesis, advanced process control was developed using the software Matlab and Simulink in conjunction with the engineering tools S7-PLCSIM Advanced and STEP 7 TIA Portal to conduct VC. A VC approach with four key steps is taken to evaluate the possibility of validating advanced process control. The steps are modeling DT of a rolling mill, model-based control design, simulation model development in Simulink, communication between the simulation model and the PLC program using S-7 TIA Portal, and PLCSIM Advanced. Also, a simulated Human-Machine Interface was designed to operate and visualize the process. VC of the rolling mill process was verified and validated by Model-in-the-Loop (MIL) and SIL simulation. The simulation gives satisfactory results as both MIL and SIL show identical outputs of the process.

Background: The Digital Twin is an increasingly trending technology that utilizes many of the key technologies relevant to the digitalization of industries and Industry 4.0, such as AI, Big Data, and IoT, to bring a virtual asset and a physical asset together to perform analysis and execute real-time decision making backed up by data (Grieves & Vickers, 2017; Rasheed et al., 2020). Current research on the benefits and challenges of Digital Twins in process industries is sparse and under-developed, and the significance of Digital Twins in their operational lifecycle phase requires investigation (Perno et al., 2020; Schleich et al., 2019; Sjödin, 2013). Research Questions: RQ1: What are the benefits of industrial process plant Digital Twins for companies in process industries? RQ2: What are the challenges that companies will face with industrial process plant Digital Twins in process industries? Literature Review: A theoretical framework was developed based on the applications, challenges, and enablers researched in other industries which acted as a foundation for the data collection process. Research Method: The thesis follows a qualitative research approach. A single-case study was employed with a large equipment supplier in the mineral processing industry, where data was collected through 17 semi-structured interviews with people possessing in-depth knowledge about the needs of the mineral processing industry. Findings: Five main benefits of industrial process plant Digital Twins in process industries were identified, Process performance, Monitoring and control, Predictive maintenance and scheduling, Business opportunities, and Safety. Correspondingly, four main challenges were identified, Perception and presentation, Privacy and security, Data management and performance, and Mutual scope and focus. Conclusions: The thesis project's managerial and theoretical implications include providing equipment suppliers in process industries with what benefits there lie with industrial process plant Digital Twins and which challenges must be overcome. By providing these benefits and challenges to equipment suppliers, they can prioritize which of these are most important to consider in their situation. The thesis contributes to the research of Digital Twins and adds to the sparse existing knowledge of what the benefits and challenges are of industrial process plant Digital Twins in process industries. The main limitation is the absence of process plant companies during the data collection phase.

Our society moves towards digitalization and the industry is not an exception. Siemenshas developed a wireless condition monitoring device called Simotics Connect in order tohelp them to move forward in the world of digitalization. The Simotics Connect has threeinbuilt sensors. One for temperature, one for vibrations and one for magnetic flux density,a product that is new in the market. This master thesis has investigated its usability forthird party motors, which has not been done.Four areas were investigated, the status in the current market, creating a motorgeometry estimation based on nameplate data, presenting a temperature model to calculatea motor’s cross section temperature and, finally, proposed a stator current model using themagnetic field measurement.Market research has shown that a space for the Simotics Connect to thrive in mostdefinitely exists.The motor geometry estimation, that is based on preliminary electromagnetic sizing,creates a digital twin for the motor that has sufficient accuracy as a tool when calculatinge.g. temperature calculations but lacks accuracy for more advanced and sensitivecalculations e.g for magnetic flux density measurement usability.The temperature model that is presented shows great accuracy when calculating thecross section temperature in the stator but the accuracy decreases for the cross sectiontemperature in the rotor.A stator current model is proposed using a proportional relationship between themagnetic flux density and stator current. The results indicates a linear relationship, thoughusing the digital twin to calculate the proportional constant were concluded to not beaccurate enough. / Sammhället rör sig idag mot digitalisering och industrin är ej ett undantag. Siemens harutvecklat en trådlös underhållsmätare kallad Simotics Connect för att hjälpa dem strävamot en värld inom digitalisering. Simotics Connect hat tre inbyggda sensorer. En för temperatur,en för vibrationer och en för magnetisk flödestäthet, vilket är nytt på marknaden.Detta masterprojekt har undersökt användningen av Simotics Connect för tredjepartsmotorer,vilket ej har gjorts tidigare.Fyra områden undersöktes, statusen på den nuvarande marknaden, en motorgeometriuppskattningmodellbaserad på namnskylsdata, en temperaturmodell för att beräknamotorns tvärsnittstemperatur och, slutligen, en statorströmmodell som använder sig avmagnetiska flödestäthetsmätningen.Marknadsundersökningen har visat att det finns ett utrymme för Simotics Connectatt blomstra inom på den nuvarande marknaden.Motorns geometriska uppskattning, som är baserad i preliminär elektromagnetiskgeometribestämning, skapar en digital tvilling av motorn som är tillräckligt noggrann föratt aggera som ett verktyg vid t.ex. temperatursberäkningar men saknar noggrannhet förmer avancerade och känsliga beräkningar, t ex för användbarhet inom magnetisk flödestäthetsberäkningar.Temperaturmodellen som presenteras visar stor noggrannhet vid beräkning av statornstvärsnittstemperatur, men noggrannheten minskar för rotorns tvärsnittstemperatur.En statorströmmodell föreslås med ett proportionellt förhållande mellan magnetflödesdensitetenoch statorströmmen. Resultaten indikerar ett linjärt förhållande, men användandetav den digitala tvillingen för att beräkna proportionell konstant konstateras attinte vara tillräckligt noggrann metod.