Adjusting products with compensatory elements using a digital twin: Model and methodology

Jaromir Konecny; Michaela Bailova; Petr Beremlijski; Michal Prauzek; Radek Martinek

doi:10.1371/journal.pone.0279988

Adjusting products with compensatory elements using a digital twin: Model and methodology

PLoS One. 2023 Jan 3;18(1):e0279988. doi: 10.1371/journal.pone.0279988. eCollection 2023.

Authors

Jaromir Konecny¹, Michaela Bailova², Petr Beremlijski², Michal Prauzek¹, Radek Martinek¹

Affiliations

¹ Department of Cybernetics and Biomedical Engineering, VSB - Technical University of Ostrava, Ostrava-Poruba, Czech Republic.
² Department of Applied Mathematics, VSB - Technical University of Ostrava, Ostrava-Poruba, Czech Republic.

Abstract

The article presents a novel strategy for reducing the geometric error of a vehicle headlamp equipped with a set of calibration screws, which represents a product assembly. Using a general method for designing and implementing a digital twin, we determined the optimal configuration for a compensatory element that minimizes the total geometric error. Formulated as a problem of constrained minimization, we solved the error using the gradient method and the Broyden-Fletcher-Goldfarb-Shanno method. Products are automatically adjusted according to this optimal setting during the manufacturing process. The results of this novel method indicate that all points can be aligned when the non-individual calibration satifies a geometrical specification of 92%. The digital twin approach was compared to the manufacturing process on 84,055 samples. Overall, 98.19% of the samples were perfectly aligned.

Copyright: © 2023 Konecny et al. This is an open access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.

Publication types

Research Support, Non-U.S. Gov't

MeSH terms

Algorithms*

Grants and funding

This work was supported by the European Regional Development Fund at the Research Centre of Advanced Mechatronic Systems project, project number CZ.02.1.01/0.0/0.0/16_019/0000867 under Operational Programme Research, Development and Education. This work was also supported by project SP2021/29, "Development of Algorithms and Systems for Control, Measurement and Safety Applications VII" of Student Grant System, VSB-TU Ostrava and SP2020/114 of Student Grant System, VSB-TU Ostrava. This work has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N°856670. The funders had no role in study design, data collection and analysis, decision to publish, or preparation of the manuscript.