Digital twin for designing a new production line

Frame story

Students play the role of being members of international team of experts in the same company. They work on the common task, that must be completed and have a successful launch in Ljubljana in May 2024. Groups are not competing but collaborating.
Students are planning a new production line. Already in the planning phase, we have to avoid wrong solutions and unnecessary costs. Augumented reality and a digital twins technology can be used for simulating production processes, predicting failures, and ensuring product quality.

Students will use augmented reality tools in conjunction with the real world. This will allow them to learn how to use the latest technologies in industrial system design. These approaches enable the development of green technologies and sustainable development.

Open Task 2024

In the task students develop a factory digital twin

  • They elaborate a production line consisting of a conveyor belt and a switch that sorts the boxes into two conveyor belts according to the size of the boxes.
  • The number of large and small boxes must be displayed.
  • The speed of the conveyor belt motor must be controlled in real and virtual environment.
Students use a programming tool Factory IO with the connection to a physical PLC (for example Simatic and TIA portal,).
Because the task is quite complex, it must be split between teams as subtasks. Part of the task will be common for all groups and part will be distributed among different groups.

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Subtasks that are common for all groups

• Prepare the architecture of the production line (conveyor belt, sensors, actuators and control systems). • Simulate the production line (Factory IO allows you to simulate the process without the connection to the real world. We can predict failures, estimate the production time etc.).

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Subtasks that are different for each group

Based on simulation each team connects its own part of the production line to the real world. Factory IO allows you to connect the virtual world to a real world. In real world we will use PLC (e.g. Simatic 1200) and some sensors and actuators, that will be connected to it. This allows us to input data from the real world into the digital twin and use the results from the digital twin to control the real world. During the meeting in Ljubljana commissioning teams (partners) assemble parts on the common physical production line.

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