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In today’s industry, the fourth industrial revolution is underway, characterized by the integration of advanced technologies such as artificial intelligence, the Internet of Things, and big data. One of the key pillars of this revolution is the technology of digital twin, which is rapidly gaining importance in various industries. However, the concept of digital twins is often misunderstood or misused as a buzzword, leading to confusion in its definition and applications. This observation inspired the authors of this paper to create their own demonstration applications that allow the control of both the real and virtual systems through automatic two-way communication and mutual influence in context of digital twins. The paper aims to demonstrate the use of digital twin technology aimed at discrete manufacturing events in two case studies. In order to create the digital twins for these case studies, the authors used technologies as Unity, Game4Automation, Siemens TIA portal, and Fishertechnik models. The first case study involves the creation of a digital twin for a production line model, while the second case study involves the virtual extension of a warehouse stacker using a digital twin. These case studies will form the basis for the creation of pilot courses for Industry 4.0 education and can be further modified for the development of Industry 4.0 educational materials and technical practice. In conclusion, selected technologies are affordable, which makes the presented methodologies and educational studies accessible to a wide range of researchers and solution developers tackling the issue of digital twins, with a focus on discrete manufacturing events.

The development of Industry 4.0, especially in the areas of interoperability and the design, implementation and use of digital twins (DT), has been enormous in recent years. This article discusses three key aspects that Industry 4.0 brings with it - virtualization through digital twins, interoperability based on the OPC UA standard, and the use of Industry 4.0’s Components – combining assets of physical production line and their Asset Administration Shells (AAS). For development and education, a methodology for an Education and Development Platform (EDP) of Interoperable Digital Twins (I-DT) has been prepared, which conveniently combines these key attributes of Industry 4.0 into a single entity. According to the proposed methodology, the pilot implementation of platform was prepared and tested on industrial technologies. The I-DT platform uses open and affordable technologies, fulfils Industry 4.0 attributes such as interoperability, virtualization, reconfigurability and modularity.

Among the most important economic activities of humankind is industry [...]

The paper presents an innovative methodology, development and implementation of a Digital Twin prototype based on a 5 Dimensional Digital Twin architecture combined with a Service-Oriented Architecture and the Industry 4.0 Component concept. The proposed implementation method separates the business logic (Digital Twin Brain) , which enables the Digital Twin to perform its new capabilities , from the domain logic , which provides the specific functionalities of the Digital Twin. The specific functionalities are provided and implemented by the Asset Administration Shell Industry 4.0 Components available as stateless services, which allowed the creation of a base of shared technical functionalities among multiple Digital Twins. The methodology and architecture were validated using real data from an industrial packaging line, where the Digital Twin leverages machine learning-based algorithms to improve efficiency and reduce production downtime. The obtained results confirm the flexibility and scalability of the proposed architecture, which allows not only predictive maintenance but also seamless integration of additional domain functions. The proposed methodology contributes to the efficient deployment of Digital Twins in multidisciplinary environments and lays the foundation for a wide range of applications in the context of Industry 5.0.

Petri nets represent a highly versatile mathematical formalism for modeling discrete event and hybrid systems. For the development of modern complex production processes for Industry 4.0, integrating these formal models with industrial communication standards is an appropriate and effective option. The main aim of the proposed article is to design a new web-based software tool for the modeling, simulation, and control of mechatronic systems with OPC Unified Architecture support. To accomplish this task, an original software solution called PetriLink is proposed. This platform leverages an intuitive graphical interface and significantly expands the formalism by combining hybrid Petri nets with Colored Petri Nets (CPN) data extensions and a reactive OPC UA subscription model. These new features greatly expand the area of systems that can be modeled and controlled, bridging the gap between theoretical academic tools and practical industrial automation. Furthermore, the structural flexibility of the implemented Petri net models enables the explicit representation of symmetric cyber-physical architectures, as well as the design of asymmetric, event-driven control strategies (e.g., using inhibitor and reset arcs) for enhanced system robustness. The platform was evaluated on a reference net of 5000 places and 2500 transitions, where an incremental dirty-flag evaluation mechanism keeps the per-step engine cost below 1 ms for sparse industrial markings and at about 350 µs for a moderate workload of one hundred concurrent tokens, yielding a speed-up of up to roughly three orders of magnitude over naive full re-evaluation and confirming consistent soft real-time behavior on commodity hardware. Offering a graphical environment for the design of discrete event and hybrid system control algorithms, it can be used for education, research and practice in cyber-physical systems (Industry 4.0).

The ongoing evolution of Industry 4.0 technologies necessitates novel and effective modes of human–machine interaction within production environments. This work presents a modular approach to the design and implementation of graphical user interfaces (GUI) in mixed reality, leveraging the Asset Administration Shell (AAS) standard. The proposed method enables the dynamic rendering of GUI elements in a Mixed Reality setting based on structured data retrieved from an AAS server. Developed for the Microsoft HoloLens 2 using the Unity engine and the Microsoft Reality Toolkit 3 (MRTK3), the system allows for the spatial placement of interface components either at predefined coordinates or in relation to specific elements of a production line model. Additionally, it incorporates a real-time distributed architecture utilizing OPC UA PubSub and MQTT protocols for processing and visualising live data. The prototype demonstrates the viability of using AAS as a flexible framework for defining and generating GUI components in immersive environments and lays the groundwork for further research into standardised, easily deployable user interface solutions for industrial applications.

This paper presents a proposal of a complex mechatronic system that enhances the effectivity of obtaining energy from renewable resources. The main focus is on the photovoltaic energy system, which obtains electricity from the conversion of solar radiation through photovoltaic crystalline silicon-based panels. The design of the complex mechatronic system consists of several steps. The structural design of the photovoltaic panel positioning unit in the form of a three-dimensional model is made in the selected modelling programming environment. Subsequently, a propulsion system is proposed for the designed structure, the functionality of which is verified in the programming environment Automated Dynamic Analysis of Mechanical Systems. The control system design using a programmable logical controller is also presented. The corresponding control algorithm is designed in the programming environment Step7 and covers the optimal positioning of photovoltaic panels. The developed application in the WinCC environment provides a visualization of the positioning control process. The conclusion is devoted to the assessment of the obtained results for the proposed complex mechatronic system for photovoltaic panel positioning in comparison with photovoltaic panels in fixed installation. The presented results were obtained by simulations.

The paper presents a low-cost driver fatigue detection camera system for older car models that do not have built-in fatigue detection systems. Based on a review of current solutions and image processing methods for face and eye detection, the Viola-Jones method for face detection and the cascade regression for eye detection were selected to enable real-time detection via smartphones and avoid the high cost of traditional systems. The proposed system has been successfully tested with real-time video under laboratory conditions.

We are now living in a time when the fourth industrial revolution is bringing new technologies with intensive digitalization of all levels of production. This paper presents a complex solution for the monitoring, diagnosis, and control of the production process, in our case, discrete event systems. The proposed solution—a mechatronic platform—further develops and extends our recent results where the overall concept was outlined and some partial tasks were studied. The present paper provides the complete structure of the proposed platform together with implementation details for all functionalities. The developed platform uses the latest technologies, such as OPC UA; industrial communication and visualization protocols and tools; and augmented reality, which enables comfortable interaction with real processes. The laboratory-scaled case study shows the qualities of the proposed solution.

The current trend in industry is the digitalisation of production processes using modern information and communication technologies, a trend that falls under the fourth industrial revolution, Industry 4.0. Applications that link the world of information technologies (IT) and operational technologies (OT) are in particular demand. On the basis of information from practice, it can be stated that there is a shortage of specialists in the labour market for the interconnection of PLCs with information and communication technologies (cloud, web, mobile applications, etc.) in Slovakia and neighbouring countries. However, this problem is beginning to affect other countries in Europe as well. The main objective of the work was to prepare case studies suitable for educational purposes, which would address the modelling and control of a virtual discrete-event system using a PLC program and its subsequent interfacing to a cloud application. Within the scope of the work, three case studies were prepared to demonstrate the control of discrete-event system using different programming systems and their communication with the developed cloud applications. These applications are to be used for data monitoring and emergency intervention of the discrete-event system. The characteristics of the prepared case studies, which combine operational and informational technologies, predestines them for use in the sphere of education of engineers for digitalisation of production processes. They can also be helpful in research on the creation of digital twins, which represent a type of symmetry between real and virtual systems.