Technical Background

Industry 4.0, often referred to as the fourth industrial revolution, represents the current trend of automation and data exchange in manufacturing technologies. It encompasses cyber-physical systems, the Internet of Things (IoT), cloud computing, and cognitive computing, leading to the creation of "smart factories." This paradigm shift enables real-time data analysis, increased efficiency, and enhanced flexibility in production processes.

*Lasi, H., Fettke, P., Kemper, H.G., Feld, T. and Hoffmann, M. (2014) 'Industry 4.0', Business & Information Systems Engineering, 6(4), pp. 239-242.

Automation involves the use of control systems, such as computers or robots, and information technologies to handle different processes and machinery in an industry. It aims to increase productivity, improve quality, and reduce human intervention. In the context of Industry 4.0, automation is elevated through interconnected systems that can make decentralized decisions.

*Groover, M.P. (2019) Automation, Production Systems, and Computer-Integrated Manufacturing. 5th edn. Pearson.

A Digital Twin is a virtual representation of a physical object or system across its lifecycle, using real-time data to enable understanding, learning, and reasoning. In manufacturing, digital twins allow for the simulation and analysis of production processes, facilitating predictive maintenance and operational efficiency. The integration of digital twins in Industry 4.0 enhances the synchronization between the physical and digital worlds.

*Tao, F., Zhang, H., Liu, A. and Nee, A.Y.C. (2019) 'Digital Twin in Industry: State-of-the-Art', IEEE Transactions on Industrial Informatics, 15(4), pp. 2405-2415. 

Siemens NX is an advanced high-end CAD/CAM/CAE software suite used for product design, engineering, and manufacturing. It offers comprehensive digital modeling and simulation tools, enabling the creation of detailed 3D models and facilitating the development of digital twins. Its integration capabilities support various aspects of product lifecycle management.

*Siemens Digital Industries Software (n.d.) 'NX for Design'. Available at: https://www.plm.automation.siemens.com/global/en/products/nx/nx-for-design.html (Accessed: 31.01.2025).

PLCSim Advanced is a Siemens software tool that allows for the simulation of programmable logic controllers (PLCs) in a virtual environment. It enables the testing and validation of control programs without the need for physical hardware, facilitating virtual commissioning and reducing development time. This tool is essential for developing and testing automation systems in a controlled, risk-free setting.

*Siemens AG (2017) 'S7-PLCSIM Advanced V2.0 – Getting Started'. Available at: https://support.industry.siemens.com/cs/attachments/109758943/Manual_VirtualCommissioningOfMachines_GettingStarted_V1.0.0_EN.pdf (Accessed: 31.01.2025).

Node-RED is an open-source flow-based development tool for visual programming, developed originally by IBM for wiring together hardware devices, APIs, and online services. In industrial automation, it is used to integrate and orchestrate data flows between various systems, enabling the creation of dashboards for monitoring and control purposes. Its flexibility and ease of use make it a valuable tool for developing IIoT applications.

*Siemens AG (2018) 'IoT2020 Using Node-RED'. Available at: https://www.automation.siemens.com/sce-static/learning-training-documents/tia-portal/advanced-communication/sce-094-100-node-red-iot2000-en.pdf (Accessed: 31.01.2025).

The Festo Modular Production System (MPS) is a comprehensive training platform designed to provide hands-on experience in industrial automation and mechatronics. Each MPS station represents a specific sub-process commonly found in automated production systems, such as distribution, sorting, and assembly. These stations can be combined to form a complete production line, offering a realistic environment for learning and experimentation.

*Festo Didactic (n.d.) 'MPS – Mechatronics learning factories'. Available at: https://www.festo.com/us/en/e/technical-education/educational-concepts/highlights/learning-factories/mps-mechatronics-learning-factories-id_31963/ (Accessed: 31.01.2025).