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Procedia CIRP 118 (2023) 110–115
16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME ‘22, Italy
Abstract
The increasing complexity and need for availability of automated guided vehicles (AGVs) pose challenges to companies, leading to a focus on
new maintenance strategies. In this paper, a smart maintenance architecture based on a digital twin is presented to optimize the technical and
economic effectiveness of AGV maintenance activities. To realize this, a literature review was conducted to identify the necessary requirements
for Smart Maintenance and Digital Twins. The identified requirements were combined into modules and then integrated into an architecture. The
architecture was evaluated on a real AGV on the battery as one of the critical components.
© 2023 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the 16th CIRP Conference on Intelligent Computation in Manufacturing Engineering
According to Bokrantz et al. smart maintenance consists of four controlling the AGV by the digital twin, the provision of
dimensions [11]. These are data-driven decision-making, information from the digital twin to the human, and the
human capital resource, internal integration and external possibility of interaction between the human and the digital
integration [11]. The dimensions are interlinked and support twin. It consists of the functional modules, which are presented
each other. Henke et al. identify six fields of action in relation in the following sections.
to smart maintenance [7]. These include the following: Joint
planning of all actors, availability-oriented maintenance, 3.1. Module AGV
flexible acting and reacting to changes, knowledge
management, requirements-based spare parts management and The AGV module is a partial component of the physical
value contribution of maintenance [7]. world and fulfills function for physical data acquisition as well
To build a smart maintenance architecture, it is suitable to as for control. The data acquired are highly depend on the
use the concept of the digital twin, as this enables a connection structure and components of the AGV. Therefore, critical
between the virtual and physical worlds and can control each components along the components of the AGV type are
other [7,12]. There are different approaches for the identified and evaluated. Typically, these are the wheels, drive
implementation of Architecture. Lee et al. define a five-stage motor, steering drive, brakes, battery, etc. Suitable
architecture with a sequential workflow [13]. According to measurement parameters are determined that, considered
Ashtari Talkhestani et al., the first three stages smart individually or in combination with each other, provide
connection, data-to-information conversion and cyber level of information about failures and maintenance requirements.
this architecture are necessary to realize a digital twin [14]. Once the measurement parameters have been identified, it must
Redelinghuys et al. form a six-stage architecture consisting of be determined whether they can be collected directly from the
sensors, data sources, local data repositories, IoT gateway, measurement equipment of the AGV or whether additional
cloud-based information repositories, simulations, and suitable measurement equipment must be installed in order to
emulations [15]. Here, humans are considered in the obtain real data from the AGV. These data can be e.g.
architecture. The human can receive information and interact odometry data, forces, electrical voltages and temperatures.
with individual elements of the architecture [15]. Ashtari Also, it comprises an interface such as the robot operating
Talkhestani et al. additionally describe the need for system (ROS) standard through which the AGV can be
synchronization and co-simulation interfaces in their controlled for maintenance purposes externally, in order
architecture [14]. They also mention the necessity of using implement a self-steering maintenance function.
models to enable a holistic representation and behavior of the
real object [14]. In their architecture, each digital twin is 3.2. Module existing IT system
assigned a unique ID [14]. Bevilacqua et al. point out the need
for continuous communication between the physical object and The existing IT system module (EITS) represents the
the virtual object [16]. They also see the need to implement function to capture data and information from existing IT
functions such as anomaly detection and decision support in the systems such as file server, databases or the computerized
architecture [16]. Qi et al. describe five essential components maintenance management system. These can be, for example,
that are necessary for the construction of a digital twin [17]. process, geometry, order, material and inventory data.
These are the ability to perceive the physical world, to capture, Furthermore, models that describe the structure and behavior
process, and transmit data, connections within the physical of the AGV are to be transferred to the digital model module.
world, connections between the physical and virtual worlds, These include electrical schematic, geometry, and simulation
and the ability to implement models and services [17]. and emulation models. Data and information such as process,
material and inventory data contained in machine-readable
3. Smart maintenance architecture for AGVs form are transferred to the data acquisition and processing
module for processing. The EITS module is assigned to the
Core idea is to develop a smart maintenance architecture that virtual world. It has a direct link to the data acquisition and
ensures an overall view of maintenance for AGVs and enable processing module and the digital model.
self-steering maintenance functions. The basic architecture
represents the basic framework for the subsequent structure of 3.3. Module data acquisition and processing
the functions within the basic architecture. The basic
architecture is intended to show the layers of the architecture. The task of the data acquisition and processing module
It could be determined that two worlds must be considered for (DAPM) is to acquire, transform, filter, standardize, cleanse
the realization of the architecture. These are the physical world and merge data from the physical world as well as from existing
and the virtual world (Fig.1). The physical world contains the IT systems. The data must be machine-readable and
AGV and the maintenance worker. The virtual world consists unambiguously assignable. In practice, it is therefore necessary
of the digital twin and the communication, connecting both to capture ID and time stamps. This allows measurement data
worlds. Communication is continuous and takes place both from different measurement devices with different
within the digital twin and between the physical world and the measurement intervals and data formats to be transformed,
virtual world. Besides that, four main communication levels are merged and standardized. The transformation should enable the
relevant for the communication between the two worlds. These data to be available in a uniform format. This is a basic
are data acquisition from the physical world, the possibility of requirement for the implementation of the module. The
112 Dionis Bozhdaraj et al. / Procedia CIRP 118 (2023) 110–115
DTn APMn
A1 An AnalysisM
ECM
CM1
IM Smart Maintenance Planning
Human IPM …
IM1 KMAG FM RP MP SPM
CMn
PM1 … KM1 FM1 RP1 MP1 SPM1
… … … … … …
IMn
KMn FMn RPn MPn SPMn
PMn
Legend:
AGV: Automated Guided Vehicle DTn: Data Type
EITS: Existing IT System RMn: Representation Model
DAPM: Data Acquisition and Processing Module SBMn: Simulation and Behavioural Models
SyncM: Synchronizaton Module AnalysisM: Analysis Module
Msync: Manual Synchronization KMAG: Knowledge Management and Action Guidelines
Async: Automatic Synchronization FM: Failure Management
IM: Information Module RP: Resource Planning
ECM: External Control Module MP: Maintenance Planning
IPM: Information Provision Module SPM: Spare Parts Management
An: Analysis CMn: Control Module
PMn: Presentation Module ITSn: IT System
APM: Acquisition and Processing Module
Information Transmission Information Transmission with Interaction
handles synchronization across modules. To enable the module functions resource planning and spare parts
synchronization, existing interfaces must be used. If no existing management. The information that is necessary from the
interfaces are available, interfaces must be created. It is module function resource planning is the availability of
necessary to define beforehand which data and information will personnel. The spare parts management function checks
be synchronized with which module levels. The whether the necessary spare parts are available. In case that the
synchronization module is a part of the virtual world in the required spare parts are available, the information about the
architecture. The synchronization module is connected with all warehouse location is also transferred. If the spare parts are not
modules. The prerequisite for this module is the creation of a available, information is transferred that shows the necessary
connection for data exchange. As long as there is no reliable spare parts as well as contact data of the supplier, the costs for
connection, no synchronization can take place. It must be the spare parts and the estimated delivery time. This
possible to repeat the connection establishment at regular information from the individual module functions is combined
intervals. This module offers the possibility of manual and transferred to the information module to generate an order.
synchronization or automated synchronization. In addition, checklists, maintenance intervals/dates, inspection
plans, components overview, manufacturer documentation,
3.7. Module smart maintenance planning internal documentation and previous maintenance reports can
be accessed interactively. These should be customizable so that
The smart maintenance planning module has the task of checklists, maintenance reports, internal documentation and
identifying, with the help of various module functions, whether maintenance intervals as well as data from maintenance staff
maintenance measures of an AGV can be remedied by the can be edited and modified by the information provision
vehicle itself or whether the intervention of a maintenance module. In addition, there is a direct link from the database
worker is necessary. Depending on the two different situations, module to the smart maintenance planning module in order to
suitable information for the maintenance activities is to be transfer the latest data, such as availability of personnel in the
provided so that the information module can generate a resource planning function or availability of spare parts in the
maintenance order either for the AGV or for the maintenance spare parts management module function.
personnel. The smart maintenance planning module comprises The resource planning module function has the task of
interconnected functions for maintenance planning, resource managing information on maintenance staff. It records whether
planning, knowledge management and action guidelines, the maintenance personnel are available, what role he plays in
failure management and spare parts management. the organization and whether he has the necessary
The maintenance planning function is used to determine qualifications to perform the demanded maintenance task.
whether a maintenance activity can be carried out by the The failure management sub module consists of the module
vehicle itself or whether the intervention of a maintenance functions failure classification and failure database. The failure
personnel is necessary. If a maintenance personnel is classification function has the task of classifying failures, e.g.
necessary, a suitable maintenance worker is identified and whether a maintenance task must be remedied by a
informed about the maintenance task. In addition, the maintenance personnel or whether the AGV can carry out the
maintenance worker receive a solution catalog, which is corresponding task on its own. The failure database function
intended to support him in carrying out the maintenance task. stores the failures that have occurred in a database. The failures
To make this possible, the smart maintenance planning module are classified according to type and severity, and assigned a
interacts with the information module. The information module unique ID and timestamp. In addition, the failure database
sends failure information that has currently occurred or will should be expandable by the maintenance personnel with
occur in the future to the maintenance planning module additional information describing the failure and the context.
function. The maintenance planning module compares the The spare parts management sub module consists of the
failure with the failure management module function. Here, the module functions digitized spare parts information and spare
failure is firstly classified. It is checked whether it is a failure parts inventories. The digitized spare parts information
that can be executed directly by the AGV itself via the external function provides the maintenance personnel with information
control module (ECM) or whether a maintenance worker is on spare parts. These are divided into assemblies, individual
required. In the case that the AGV can repair the failure itself, parts or raw materials and provide the necessary information
the module function sends a feedback to the information about costs, suppliers including contact details and the
module that contains information for the order generation. dimensions of the spare parts. The spare parts inventories
Possible failures where self-steering maintenance can be provide information on whether and which spare parts are
applied are wheels, drive motor, steering drive, brakes, battery, available, as well as information on delivery times for
etc. If the failure cannot be repaired by the AGV, information unavailable spare parts. It also shows at which locations the
is compiled via the module functions spare parts management, available spare parts are located. Optionally, this module can
failure management, knowledge management and action be extended so that a purchase requisition is issued
guidelines and resource planning to enable order generation. automatically if required. The smart maintenance planning
This information includes the failure type, time of failure and module is a part of the digital twin digital twin in the virtual
failure severity from the module function failure management world. It is connected to the database, the information module
and solutions of the failure type with action guidelines from the and the information provision module.
module function knowledge management and action
guidelines. In addition, further information is provided from
114 Dionis Bozhdaraj et al. / Procedia CIRP 118 (2023) 110–115
The data acquisition and processing module was industry and how well the smart maintenance architecture
implemented in an automated and rule-based manner, so that performs in the industry.
data sets that are available in different data formats are
converted. In addition, different measurement intervals are
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