Towards automatic configuration and programming of a manufacturing cell

Manufacturing industries are moving from mass production towards customized production, aiming for high-quality products with innovative technologies, low prices, and high reliability. A reconfigurable manufacturing system (RMS) is an attractive approach to facilitate the movement toward such flexible manufacturing systems. However, reconfiguration and programming of RMS are time-consuming and labor-intensive. Industry 4.0 technologies (such as robotics, digital twin technology, and IoT solutions) decrease human interaction in the preparation phase of a new production series. One challenge that industry 4.0 does not address is a flexible electrification of the system. The lack of electrical outlets limits the available space on the shop floor, and extensive cabling constrains the motion of humans and machines in the same area. This paper solves these challenges by proposing a highly flexible RMS system with advanced robotics, a digital twin programming interface, and a wireless power transfer (WPT) solution. Experimental results, through simulations and verification by laboratory experiments, show great potential in the reduction of human interaction and time to set up a new manufacturing line. [Display omitted] •Proposing a new RMS in which a mobile robot can reconfigure the system.•Rearranging, and monitoring the proposed system using a digital twin solution.•Proposing static and dynamic WPT as industry 4.0 technology for RMS.•Retrofitting old manufacturing machines with industry 4.0 technology.•Simulating and verifying through laboratory experiments and video presentations.