FPGA-Based Sensors for Distributed Digital Manufacturing Systems: A State-of-the-Art Review

The combination of distributed digital factories (D²Fs) with sustainable practices has been proposed as a revolutionary technique in modern manufacturing. This review paper explores the convergence of D²F with innovative sensor technology, concentrating on the role of Field Programmable Gate Arrays (FPGAs) in promoting this paradigm. A D²F is defined as an integrated framework where digital twins (DTs), sensors, laser additive manufacturing (laser-AM), and subtractive manufacturing (SM) work in synchronization. Here, DTs serve as a virtual replica of physical machines, allowing accurate monitoring and control of a given manufacturing process. These DTs are supplemented by sensors, providing near-real-time data to assure the effectiveness of the manufacturing processes. FPGAs, identified for their re-programmability, reduced power usage, and enhanced processing compared to traditional processors, are increasingly being used to develop near-real-time monitoring systems within manufacturing networks. This review paper identifies the recent expansions in FPGA-based sensors and their exploration within the D²Fs operations. The primary topics incorporate the deployment of eco-efficient data management and near-real-time monitoring, targeted at lowering waste and optimizing resources. The review paper also identifies the future research directions in this field. By incorporating advanced sensors, DTs, laser-AM, and SM processes, this review emphasizes a path toward more sustainable and resilient D²Fs operations.