Search Results (302)

Autonomous surgery involves surgical tasks performed by a robot with minimal or no human involvement. Thanks to its precise automation, surgical robotics offers significant benefits in enhancing the consistency, safety, and quality of procedures, driving its growing popularity. However, ensuring the safety of autonomous surgical robotic systems remains a significant challenge. To address this, we propose a simulation-based validation method to detect potential safety issues in the software of surgical robotic systems, complemented by a digital twin to estimate the gap between simulation and reality. The validation framework consists of a test case generator and a monitor for validating properties and evaluating the performance of the robotic system during test execution. Using a robotic arm for needle insertion as a case study, we present a systematic test case generation method that ensures effective coverage measurement for a three-dimensional, irregular model. Since no simulation can perfectly replicate reality due to differences in sensing and actuation, the digital twin bridges the gap between simulation and the physical robotic arm. This integration enables us to assess the discrepancy between virtual simulations and real-world operations by verifying whether the data from the simulation accurately predicts real-world outcomes. Through extensive experimentation, we identified several flaws in the robotic software. Co-simulation within the digital twin framework has highlighted these discrepancies that should be considered. Full article

The global infrastructure industry is faced with increasing system complexity and requirements driven by the Sustainable Development Goals, technological advancements, and the shift from Industry 4.0 to human-centric 5.0 principles. Coupled with persistent infrastructure investment deficits, these pressures necessitate improved methods for efficient requirements management and validation. While digital twins promise transformative real-time decision-making, reliance on static unstructured data formats inhibits progress. This paper presents a novel framework that integrates Building Information Modelling (BIM) and Model-Based Systems Engineering (MBSE), using Linked Data principles to preserve semantic meaning during information exchange between physical abstractions and requirements. The proposed approach automates a step of compliance validation against regulatory standards explored through a case study, utilising requirements from a high-speed railway station fire safety system and a modified duplex apartment digital model. The workflow (i) digitises static documents into machine-readable MBSE formats, (ii) integrates structured data into dynamic digital models, and (iii) creates foundations for data exchange to enable compliance validation. These findings highlight the framework’s ability to enhance traceability, bridge static and dynamic data gaps, and provide decision-making support in digital twin environments. This study advances the application of Linked Data in infrastructure, enabling broader integration of ontologies required for dynamic decision-making trade-offs. Full article

In this work, we propose the use of a reinforcement learning (RL) agent for the control of a cascade hydropower plant system. Generally, this job is handled by power plant dispatchers who manually adjust power plant electricity production to meet the changing demand set by energy traders. This work explores the more fundamental problem with the cascade hydropower plant operation of flow control for power production in a highly nonlinear setting on a data-based digital twin. Using deep deterministic policy gradient (DDPG), twin delayed DDPG (TD3), soft actor-critic (SAC), and proximal policy optimization (PPO) algorithms, we can generalize the characteristics of the system and determine the human dispatcher level of control of the entire system of eight hydropower plants on the river Drava in Slovenia. The creation of an RL agent that makes decisions similar to a human dispatcher is not only interesting in terms of control but also in terms of long-term decision-making analysis in an ever-changing energy portfolio. The specific novelty of this work is in training an RL agent on an accurate testing environment of eight real-world cascade hydropower plants on the river Drava in Slovenia and comparing the agent’s performance to human dispatchers. The results show that the RL agent’s absolute mean error of 7.64 MW is comparable to the general human dispatcher’s absolute mean error of 5.8 MW at a peak installed power of 591.95 MW. Full article

Global ambitions for net-zero emissions and resource circularity are propelling industry from linear “make-use-dispose”models toward closed-loop value creation. Remanufacturing, which aims to restore end-of-life products to a “like-new” condition, plays a central role in this transition. However, its stochastic inputs and complex, multi-stage processes pose significant challenges to traditional production planning methods. This study delivers an integrated overview of remanufacturing scheduling by combining a systematic bibliometric review of 190 publications (2005–2025) with a critical synthesis of modelling approaches and enabling technologies. The bibliometric results reveal five thematic clusters and a 14% annual growth rate, highlighting a shift from deterministic, shop-floor-focused models to uncertainty-aware, sustainability-oriented frameworks. The scheduling problems are formalised to capture features arising from variable core quality, multi-phase precedence, and carbon reduction goals, in both centralised and cloud-based systems. Advances in human–robot disassembly, vision-based inspection, hybrid repair, and digital testing demonstrate feedback-rich environments that increasingly integrate planning and execution. A comparative analysis shows that, while mixed-integer programming and metaheuristics perform well in small static settings, dynamic and large-scale contexts benefit from reinforcement learning and hybrid decomposition models. Finally, future directions for dynamic, collaborative, carbon-conscious, and digital-twin-driven scheduling are outlined and investigated. Full article

Artificial intelligence (AI) is now the computational core of smart building automation, acting across the entire cyber–physical stack. This review surveys peer-reviewed work on the integration of AI with indoor environmental quality (IEQ) and energy performance, distinguishing itself by presenting a holistic synthesis of the complete technological evolution from IoT sensors to generative AI. We uniquely frame this progression within a human-centric architecture that integrates digital twins of both the building (DT-B) and its occupants (DT-H), providing a forward-looking perspective on occupant comfort and energy management. We find that deep reinforcement learning (DRL) agents, often developed within physics-calibrated digital twins, reduce annual HVAC demand by 10–35% while maintaining an operative temperature within ±0.5 °C and CO₂ below 800 ppm. These comfort and IAQ targets are consistent with ASHRAE Standard 55 (thermal environmental conditions) and ASHRAE Standard 62.1 (ventilation for acceptable indoor air quality); keeping the operative temperature within ±0.5 °C of the setpoint and indoor CO₂ near or below ~800 ppm reflects commonly adopted control tolerances and per-person outdoor air supply objectives. Regarding energy impacts, simulation studies commonly report higher double-digit reductions, whereas real building deployments typically achieve single- to low-double-digit savings; we therefore report simulation and field results separately. Supervised learners, including gradient boosting and various neural networks, achieve 87–97% accuracy for short-term load, comfort, and fault forecasting. Furthermore, unsupervised models successfully mine large-scale telemetry for anomalies and occupancy patterns, enabling adaptive ventilation that can cut sick building complaints by 40%. Despite these gains, deployment is hindered by fragmented datasets, interoperability issues between legacy BAS and modern IoT devices, and the computer energy and privacy–security costs of large models. The key research priorities include (1) open, high-fidelity IEQ benchmarks; (2) energy-aware, on-device learning architectures; (3) privacy-preserving federated frameworks; (4) hybrid, physics-informed models to win operator trust. Addressing these challenges is pivotal for scaling AI from isolated pilots to trustworthy, human-centric building ecosystems. Full article

Most of the failures during the actual operation of equipment are caused by improper human operation, tools, spare parts, and environmental factors. These faults are routine. Conventional faults have been validated during equipment development, testing, identification, and maintenance processes, with clear definitions and clear fault tree analysis (FTA) conclusions. Digital twins can offer rapid and interactive diagnostic capabilities for routine equipment failures. To enhance the efficiency of routine fault diagnosis and the interactive experience of the diagnosis process, this paper proposes a digital twin-based equipment routine fault diagnosis model. On this basis, considering the excellent interactivity of the Interactive Electronic Technical Manual (IETM), a conventional equipment fault diagnosis scheme based on twin data and IETM is designed. This scheme converts the equipment fault tree into an IETM fault data model (DM), which is structured and stored in a database to form a fault database. Using real-time twin data of equipment as input, the FTA method is adopted to perform step-by-step fault diagnosis and isolation guidance operation through the IETM process DM combined with fault, while providing maintenance operation guidance. When the real-time twin data of the equipment is not completely consistent with the fault information in the fault library, the case analysis method is used to calculate the similarity between the real-time twin data of the equipment and the clearly defined fault symptom information in the fault library. Based on the set similarity threshold, IETM pushes fault DMs above the threshold for corresponding fault diagnosis isolation guidance. Full article

Bridge cranes generally have a significant disparity between their actual service life and design life. If they are scrapped according to the design life, it is likely to result in resource wastage or pose potential safety hazards due to extended service. Existing studies have not thoroughly examined the coupling relationship among actual working conditions, structural damage, and load-matching strategies. It is difficult to achieve real-time and accurate adaptation between loads and the carrying capacity of equipment, and thus cannot effectively narrow this life gap. To this end, this paper defines a digital twin system framework for crane load adaptive matching, constructs a load adaptive matching optimization model, proposes a method for developing a digital twin system for bridge crane load adaptive matching, and builds a digital twin system platform centered on virtual-real mapping, IoT connectivity, and data interaction. Detailed experimental verification was conducted using the DQ40 kg-1.8 m-1.3 m light-duty bridge crane. The results demonstrate that this method and system can effectively achieve dynamic matching between the load and real-time carrying capacity. While ensuring the service life exceeds the design life, the difference between the two is controlled at around 3467 cycles, accounting for approximately 0.000462% of the design life. This significantly improves the equipment’s operational safety and resource utilization efficiency, breaks through the limitations of load reduction schemes formulated based on human experience under the traditional regular inspection mode, and provides a scientific load-matching decision-making basis and technical support for special equipment inspection institutions and users. Full article

This paper proposes a novel and comprehensive framework for the integration of manufacturing management processes, spanning strategic and operational levels, within and across organizational boundaries. The framework combines a robust set of technologies—such as cyber-physical systems, digital twins, AI, and blockchain—designed to support real-time decision-making, interoperability, and collaboration in Industry 4.0 and 5.0 contexts. Implemented and validated in a Portuguese manufacturing group comprising three interoperating factories, the framework demonstrated its ability to improve agility, coordination, and stakeholder integration through a multi-layered architecture and modular software platform. Quantitative and qualitative feedback from 32 participants confirmed enhanced decision support, operational responsiveness, and external collaboration. While tailored to a specific industrial setting, the results highlight the framework’s scalability and adaptability, positioning it as a meaningful contribution toward sustainable, human-centric digital transformation in manufacturing environments. Full article

Industry 5.0 introduces a new paradigm where digital technologies support sustainable and human-centric industrial development. Within this context, resilience-based maintenance (RBM) emerges as a forward-looking maintenance strategy focused on system adaptability, fault tolerance, and recovery capacity under uncertainty. This article presents a systematic literature review (SLR) on RBM in the context of Maintenance 5.0. The review follows the PRISMA methodology and incorporates bibliometric and content-based analyses of selected publications. Key findings highlight the integration of AI methods, such as machine learning and digital twins, in enhancing system resilience. The results demonstrate how RBM aligns with the pillars of Industry 5.0, sustainability, and human-centricity, by reducing resource consumption and improving human–machine interaction. Research gaps are identified in AI explainability, sector-specific implementation, and ergonomic integration. The article concludes by outlining directions for developing Maintenance 5.0 as a strategic concept for resilient, intelligent, and inclusive industrial systems. Full article

The integration of robotics and mobile networks (5G/6G) through the Internet of Robotic Things (IoRT) is revolutionizing telemedicine, enabling remote physician participation in scenarios where specialists are scarce, where there is a high risk to them, such as in conflicts or natural disasters, or where access to a medical facility is not possible. Nevertheless, touching a human safely with a robotic arm in non-engineered or even out-of-hospital environments presents substantial challenges. This article presents a novel IoRT approach for healthcare in or from remote areas, enabling interaction between a specialist’s hand and a robotic hand. We introduce the IoRT-in-hand: a smart, lightweight end-effector that extends the specialist’s hand, integrating a medical instrument, an RGB camera with servos, a force/torque sensor, and a mini-PC with Internet connectivity. Additionally, we propose an open-source Android app combining MQTT and ROS for real-time remote manipulation, alongside an Edge–Cloud architecture that links the physical robot with its Digital Twin (DT), enabling precise control and 3D visual feedback of the robot’s environment. A proof of concept is presented for the proposed tele-robotic system, using a 6-DOF manipulator with the IoRT-in-hand to perform an ultrasound scan. Teleoperation was conducted over 2300 km via a 5G NSA network on the operator side and a wired network in a laboratory on the robot side. Performance was assessed through human subject feedback, sensory data, and latency measurements, demonstrating the system’s potential for remote healthcare and emergency applications. The source code and CAD models of the IoRT-in-hand prototype are publicly available in an open-access repository to encourage reproducibility and facilitate further developments in robotic telemedicine. Full article

The retrofitting of legacy systems enables upgrades that extend the lifespan of outdated equipment, improve efficiency, and reduce environmental impacts. This manuscript builds on existing approaches to retrofitting legacy systems using Industry 4.0 technologies. Therefore, it explores how the proposed modernization envisions the transition from Industry 4.0 to Industry 5.0, which emphasizes human-centric approaches, sustainability, and resilience. Tools such as RAMI 4.0 (a reference architecture model for Industry 4.0), Lean Six Sigma (a methodology for process improvement), and Big Data analytics are highlighted throughout the text as essential for optimizing processes and ensuring alignment with global challenges, including resource efficiency and environmental sustainability. This work addresses both conceptual and technical aspects of system modernization. It provides a comprehensive framework for retrofitting systems and integrating advanced technologies such as digital twins. These efforts ensure that industries are prepared for the evolving demands of Industry 4.0 and beyond. Full article

Sociotechnical systems (STSs) are generally assumed to be systems that incorporate humans and technology, strongly depending on a sustainable equilibrium between the following nondeterministic social context ingredients: social structures, roles, and rights, as well as the designers’ Holy Grail, the deterministic nature of the underlying technical system. The fact that the relevant social concepts are more mature than the supporting technologies qualifies the digital transformation of sociotechnical systems as a reengineering rather than an engineering endeavor. Preserving the social mission throughout the digital transformation process in varying social contexts is mandatory, making the digital twins (DT) methodology application a contemporary research hotspot. In this research, we combined continuous transformation STS theory principles, an observer-based system-of-sociotechnical-systems (SoSTS) architecture model, and digital twinning methods to address common STS context representation challenges. Additionally, based on model-driven systems engineering methodology and meta-object-facility principles, the research specifies the universal meta-concepts and meta-modeling templates, supporting the creation of arbitrary sociotechnical systems’ external context digital twins. Due to the inherent diversity, significantly influenced by geopolitical, economic, and cultural influencers, a higher education external context specialization illustrates the reusability potentials of the proposed universal meta-concepts. Substituting higher-education-related meta-concepts and meta-models with arbitrary domain-dependent specializations further fosters the proposed universal meta-concepts’ reusability. Full article

Simulators play a critical role in the development and testing of Industry 4.0 and Industry 5.0 applications. However, few studies have examined their capabilities beyond physics modeling, particularly in terms of connectivity and integration within broader robotic ecosystems. This review addresses this gap by focusing on ROS-compatible simulators. Using the SEGRESS methodology in combination with the PICOC framework, this study systematically analyzes 65 peer-reviewed articles published between 2021 and 2025 to identify key trends, capabilities, and application domains of ROS-integrated robotic simulators in industrial and manufacturing contexts. Our findings indicate that Gazebo is the most commonly used simulator in Industry 4.0, primarily due to its strong compatibility with ROS, while Unity is most prevalent in Industry 5.0 for its advanced visualization, support for human interaction, and extended reality (XR) features. Additionally, the study examines the adoption of ROS and ROS 2, and identifies complementary communication and integration technologies that help address the current interoperability challenges of ROS. These insights are intended to inform researchers and practitioners about the current landscape of simulation platforms and the core technologies frequently incorporated into robotics research. Full article

Green manufacturing has emerged as a critical objective in the evolution of advanced production systems. Although digital twin technology is widely recognized for enhancing efficiency and promoting sustainability, the majority of existing research focuses exclusively on physical systems. They neglect the impact of soft systems, including human behavior, decision-making, and operational strategies. To address this limitation, the present study introduces an innovative hybrid digital twin model that integrates both physical and soft systems to support green manufacturing initiatives comprehensively. The primary contributions of this work are threefold. First, a novel hybrid architecture is developed by coupling real-time physical data with virtual soft system components that simulate factory operations. Second, lean production principles are systematically incorporated into the soft system, thereby facilitating reduced energy consumption and minimizing environmental impact. Third, a parameter-driven programming model is formulated to correlate critical variables with green performance metrics, and a genetic algorithm is utilized to optimize these variables, ultimately enhancing sustainability outcomes. This integrated approach not only expands the applicability of digital twin technology but also offers a data-driven decision-support tool for the advancement of green manufacturing practices. Full article

The integration of digital twin technology with robotic automation holds significant promise for advancing sustainable horticulture in controlled environment agriculture. This article presents DigiHortiRobot, a novel AI-driven digital twin architecture tailored for hydroponic greenhouse systems. The proposed framework integrates real-time sensing, predictive modeling, task planning, and dual-arm robotic execution within a modular, IoT-enabled infrastructure. DigiHortiRobot is structured into three progressive implementation phases: (i) monitoring and data acquisition through a multimodal perception system; (ii) decision support and virtual simulation for scenario analysis and intervention planning; and (iii) autonomous execution with feedback-based model refinement. The Physical Layer encompasses crops, infrastructure, and a mobile dual-arm robot; the virtual layer incorporates semantic modeling and simulation environments; and the synchronization layer enables continuous bi-directional communication via a nine-tier IoT architecture inspired by FIWARE standards. A robot task assignment algorithm is introduced to support operational autonomy while maintaining human oversight. The system is designed to optimize horticultural workflows such as seeding and harvesting while allowing farmers to interact remotely through cloud-based interfaces. Compared to previous digital agriculture approaches, DigiHortiRobot enables closed-loop coordination among perception, simulation, and action, supporting real-time task adaptation in dynamic environments. Experimental validation in a hydroponic greenhouse confirmed robust performance in both seeding and harvesting operations, achieving over 90% accuracy in localizing target elements and successfully executing planned tasks. The platform thus provides a strong foundation for future research in predictive control, semantic environment modeling, and scalable deployment of autonomous systems for high-value crop production. Full article