| Περίληψη: | Traditional manufacturing, through the fourth industrial revolution, moves to each next phase that
if digitalization. This revolution transforms the manufacturing systems into modern, digitalized ones.
However, the digital transformation of manufacturing requires flexible and adaptive production
systems which however lead to increased system’s complexity. Moreover, the lack of
communication among the existing information and communications (ICT) tools in the production
and the absence of infrastructure for the automated management and the re-use of knowledge can
lead to difficulties to the communication and the transmission of information. Summarising the
above, existing production systems utilize ICT tools which work in isolation without interfacing or
communication among them. Consequently, often, the information but also the knowledge remains
in the limits of concrete department of enterprise without communicating it to the rests functions
of the company so as to be informed aiming to make accurate decisions based on the real-condition
of the production.
This thesis, considering the main challenges of the digitalized manufacturing enabled by the 4 th
Industrial revolution, is focused on the design and development of a cyber-physical system capable
of sensing and capturing data from shop-floor in near real-time and transmitting them using wireless
sensor networks and industrial communication protocols to a cloud platform. Once the data is
captured is analysed, and the meaningful information is delivered to a multi-criteria decision-making
algorithm for adaptive scheduling as well as to a condition-based maintenance tool which is also
supported by Augmented reality technology.
The main contribution of the present thesis is summarized in the bullets below:
1. Investigation of the needs and challenges of manufacturing systems towards digitalized
manufacturing enabled by the 4 th Industrial revolution and the Industrial Internet of Things.
8Increased need for interoperability, communication, and adaptability through the effective and
efficient integration between the physical and the cyber systems.
2. Design and development of a low-cost, reliable and reconfigurable monitoring system capable
of sensing the real shop-floor condition and transmitting the captured data though wireless
sensor networks and industrial communication protocols and standards. Through the proposed
system can be identified and calculated the machine tool status, the machine tool actual
machining time, the energy consumption, as well as the condition of the running tasks.
3. Definition and calculation of meaningful performance indicators (KPIs monitoring) in near real-
time, considering among others machine tool status, actual machining time, machine tool energy
consumption, remaining operating time between failure, machine tool availability and utilization.
4. Design and development of an algorithm and tool for adaptive production scheduling based on
the real information captured from shop-floor. Interface and data exchange between the
monitoring system and the scheduling algorithm. A multi-criteria algorithm capable of
recognizing and receiving meaningful information from shop-floor and generating feasible
alternative schedules quickly and accurately. The monitoring system senses the shop-floor
condition and in case it recognizes any disturbances, inform the scheduling algorithm and tool
and also sends to it the current shop-floor condition aiming to use the provided information and
reschedule based on that.
5. Design and development of an algorithm for condition-based maintenance of machine tools
supported by Augmented reality technology. Remote maintenance of machine tools based on
their real condition, recognizing their status and the remaining operating time between failures.
The AR remote maintenance application is capable of receiving in near real-time the machine
tools condition, capturing the problem using the AR mobile application and receiving thought AR
the required instructions aiming to perform the maintenance of the machine tools efficiently,
quickly and cost-effectively.
6. Development of the cyber-physical system in a cloud platform. The developed applications can
be provided as service through the cloud platform and also it enables ubiquitous data access and
interoperability among the different tools and methods. Through the developed cloud platform
multi user can have access to the application increasing collaboration and efficient data
exchange.
7. Implementation and validation of the developed cyber-physical system in real industrial
environments with real industrial data. The different tools and methods of the CPS are
implemented in different industrial cases considering a machine shop-floor, a mould-making
industry and a white goods industry. The results of the implementation revealed the main
benefits of the proposed system compared to the traditional way of manufacturing systems
operation as well as compared to existing approaches.
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