Cycle Time Reduction in Production Systems via Digital Twin-Based Compensation of Pneumatic Reaction Times

Research output: Contribution to book/Conference proceedings/Anthology/ReportConference contributionContributedpeer-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 languageEnglish
Title of host publicationIECON 2025 - 51st Annual Conference of the IEEE Industrial Electronics Society
PublisherIEEE Computer Society
ISBN (electronic)979-8-3315-9681-1
ISBN (print)979-8-3315-9682-8
Publication statusPublished - 2025
Peer-reviewedYes

Publication series

SeriesAnnual Conference of Industrial Electronics Society (IECON)
ISSN2162-4704

Conference

Title51st Annual Conference of the IEEE Industrial Electronics Society
Abbreviated titleIECON 2025
Conference number51
Duration14 - 17 October 2025
Website
LocationHotel Meliá Castilla
CityMadrid
CountrySpain

External IDs

ORCID /0000-0002-1093-2149/work/203811175

Keywords

Keywords

  • adaptive control, digital twin, online optimization, pneumatic actuators, reaction time compensation, virtual commissioning