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Design and Implementation of Universal Cyber-Physical Model for Testing Logistic Control Algorithms of Production

Ján Vachálek1, Dana Šišmišová1, Pavol Vašek2

  • 1Faculty of Mechanical Engineering, Slovak University of Technology in Bratislava, Námestie slobody 17, 812 31 Bratislava, Slovakia.

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Summary

A universal cyber-physical system (CPS) enables testing logistics optimization algorithms with a digital twin. This physical model replicates production lines, reducing costs and risks before real-world implementation.

Keywords:
assembly linescolor sensorcyber-physical modeldigital twinlogistic control algorithmsrobotic workplace

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Area of Science:

  • Industrial Engineering
  • Cyber-Physical Systems
  • Manufacturing Optimization

Background:

  • Production facilities increasingly seek to optimize logistics for efficiency and reduced idle time.
  • Digital twins are standard for virtualizing production processes, but physical implementation risks remain.
  • Existing production infrastructure and costs deter rapid adoption of simulated optimization changes.

Purpose of the Study:

  • To design and implement a universal cyber-physical model for simulating and optimizing production logistics.
  • To provide a safe, cost-effective method for testing logistics algorithms using a digital twin.
  • To address concerns regarding the physical implementation of optimization changes in functional production lines.

Main Methods:

  • Developed a modular cyber-physical system (CPS) to substitute physical connections for digital twins.
  • The CPS replicates physical inputs and outputs of a real production line.
  • Validated the model using a configuration simulating a robotic assembly workplace and its logistics.

Main Results:

  • The universal CPS physically reproduces real production conditions for virtual verification.
  • Advanced logistics algorithms can be tested and debugged using the digital twin outside the production line.
  • Significant reduction in optimization costs by testing in the physical model instead of the actual production line.

Conclusions:

  • The developed universal cyber-physical model offers a pragmatic solution for testing and validating logistics optimization.
  • It mitigates risks and reduces costs associated with implementing changes in functional production environments.
  • The system's versatility is demonstrated through its application in simulating a robotic assembly workplace.