Aston University BEng Mechanical Engineering student Xavi Parmar has been exploring digital twin technology through his final-year project, making use of the advanced facilities at the Greater Birmingham and Solihull Institute of Technology (GBSIoT) Hub. By leveraging the Learning Factory and its state-of-the-art equipment, Xavi has been developing a digital twin model of Festo’s Cyber-Physical Lab (CP Lab) to assess its performance and efficiency.
Bridging the Gap Between Physical and Digital Systems
With Industry 4.0 revolutionising the manufacturing sector, digital twin technology has become an essential tool in smart manufacturing, offering benefits such as improved efficiency, remote monitoring, and predictive maintenance. Xavi’s project aims to create a high-fidelity digital replica of the CP Lab, integrating real-world functions and collecting valuable efficiency data.
Using CIROS Studio, a powerful simulation platform, he started by modelling an individual workstation before expanding to a fully developed digital twin of the entire CP Lab. The integration of Manufacturing Execution System 4 (MES4) allowed the simulation to process production orders and perform data analysis, offering insights into overall equipment effectiveness (OEE).
Key Findings and Real-World Impact
The project’s results demonstrated that the digital model successfully mirrored the physical system in terms of workstation performance and production flow. However, discrepancies in efficiency were observed. The digital twin predicted lower efficiency levels due to overestimated theoretical values in MES4, yet process timelines closely matched real-world conditions, confirming the validity of the digital simulation.
“This study showcases the potential of digital twins in manufacturing, while also highlighting the need for advanced data analysis and real-time data integration to improve accuracy and automation,” said Xavi.
Future Developments in Smart Manufacturing
As digital twin technology continues to evolve, future research should focus on refining real-time data integration, improving automation capabilities, and testing across more advanced cyber-physical systems. Xavi’s work at GBSIoT Hub underscores the importance of hands-on experience in developing the next generation of smart manufacturing professionals.
His project exemplifies how collaboration between industry and academia at GBSIoT provides students with the resources and expertise necessary to drive innovation in manufacturing. Through access to cutting-edge equipment and industry-relevant training, students like Xavi are gaining invaluable skills that will shape the future of digital manufacturing.
To see the project in action, watch the simulation video here: Project Video.
