Cycle Time Reduction in Production Systems via Digital Twin-Based Compensation of Pneumatic Reaction Times
Research output: Contribution to book/Conference proceedings/Anthology/Report › Conference contribution › Contributed › peer-review
Contributors
Abstract
In event-based control systems, actuator operations are typically triggered by physical sensor signals to ensure process safety. However, this can lead to systematic delays, especially in pneumatic systems, due to system-related reaction times. This paper presents a method to compensate such delays by statistically advancing control signals without the need for additional sensors. A bidirectionally coupled digital twin, based on virtual commissioning models, continuously evaluates live data and derives optimized advance signals during operation. The method integrates event-based control with time-based triggering and employs a hybrid approach combining empirical quantiles with analytical confidence intervals to maintain safe operation. Validated in a testbed under realistic industrial conditions, the approach achieves an average time saving of 315ms per compensated transition. The system architecture decouples real-time PLC execution from non-real-time analysis, enabling scalable integration with diverse control and simulation platforms. The results demonstrate the potential of digital twins for active, data-driven optimization in discrete manufacturing systems.
Details
| Original language | English |
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| Title of host publication | IECON 2025 - 51st Annual Conference of the IEEE Industrial Electronics Society |
| Publisher | IEEE Computer Society |
| ISBN (electronic) | 979-8-3315-9681-1 |
| ISBN (print) | 979-8-3315-9682-8 |
| Publication status | Published - 2025 |
| Peer-reviewed | Yes |
Publication series
| Series | Annual Conference of Industrial Electronics Society (IECON) |
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| ISSN | 2162-4704 |
Conference
| Title | 51st Annual Conference of the IEEE Industrial Electronics Society |
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| Abbreviated title | IECON 2025 |
| Conference number | 51 |
| Duration | 14 - 17 October 2025 |
| Website | |
| Location | Hotel Meliá Castilla |
| City | Madrid |
| Country | Spain |
External IDs
| ORCID | /0000-0002-1093-2149/work/203811175 |
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Keywords
ASJC Scopus subject areas
Keywords
- adaptive control, digital twin, online optimization, pneumatic actuators, reaction time compensation, virtual commissioning