Process Modelling of an Analytic Control Machine in Virtual Reality Platform

While the combination of virtual reality (VR), industrial internet of things (IIoT) and digital twin (DT) can promote the integration of the physical world (real) and the digital world (virtual), one of the most important challenges that companies face is the choice of architecture. This study intends to utilize VR, IIoT, DT advantages and to reduce some adverse effects the constituent processes produce when they are individually applied. This bridges the existing gap between the physical and digital machines to enable near real-time monitoring control of the manufacturing process. In the realization of this paradigm shift, we use of IIoT infrastructures by adopting a bi-directional communication protocol for conveyance of data and information between the physical and virtual models in hardware in the loop or software in loop configuration. This study takes into account user case industrial application for the formation of silica scale and methods of reducing its production. In systems operating above pH 8.5, magnesium silicate is very likely to form due to the presence of magnesium hydroxide Mg(OH)(2) and silicate (SiO(4))(4−) ions. In this research work, the developed platform (VR, IIoT and DT) is used to remotely monitor and control the process that prevents silica scale formation by maintaining an acidic solution (pH < 6.7). A supervisory control is achieved using VR whereby instructions and commands sent to the physical station for execution. The data collected is stored in a data lake and is used to find the PID controller trends for pH 4 dosing and gain actionable insights. Analysis of the data is done by utilization of visualization schemes, diagrams and infographics. Results show the achievement of near real-time control (correlation coefficient at 99.92%) of a cyber-physical machine using VR by the adoption of bi-directional communication between the physical and virtual models in an immersive environment.