Real-Time Manufacturing Machine and System Performance Monitoring Using Internet of Things

This paper introduces a framework to assess the performance of manufacturing systems using hybrid simulation in real time. Continuous and discrete variables of different machines are monitored to analyze performance using a virtual environment running synchronous to plant floor equipment as a reference. Data are extracted from machines using industrial Internet of Things solutions. Productivity and reliability of a physical system are compared in real time with data from a hybrid simulation. The simulation uses discrete-event systems to estimate performance metrics at a system level, and continuous dynamics at a machine level to monitor input and output variables. Simulation outputs are used as a reference to detect abnormal conditions based on deviations of real outputs in different stages of the process. This monitoring method is implemented in a fully automated manufacturing system testbed with robots and CNC machines. Machines are integrated on an Ethernet/IP control network using a programmable logic controller to coordinate actions and transfer data. Results demonstrated the capacity to perform real-time monitoring and capture performance errors within confidence intervals.