Industry 4.0 is the fourth industrial revolution consisting of the digitalization of processes facilitating an incremental value chain. Smart Manufacturing (SM) is one of the branches of the Industry 4.0 regarding logistics, visual inspection of pieces, optimal organization of processes, machine sensorization, real-time data adquisition and treatment and virtualization of industrial activities. Among these tecniques, Digital Twin (DT) is attracting the research interest of the scientific community in the last few years due to the cost reduction through the simulation of the dynamic behaviour of the industrial plant predicting potential problems in the SM paradigm. In this paper, we propose a new DT design concept based on external service for the transportation of the Automatic Guided Vehicles (AGVs) which are being recently introduced for the Material Requirement Planning satisfaction in the collaborative industrial plant. We have performed real experimentation in two different scenarios through the definition of an Industrial Ethernet platform for the real validation of the DT results obtained. Results show the correlation between the virtual and real experiments carried out in the two scenarios defined in this paper with an accuracy of 97.95% and 98.82% in the total time of the missions analysed in the DT. Therefore, these results validate the model created for the AGV navigation, thus fulfilling the objectives of this paper.

Positioning asynchronous architectures based on time measurements are reaching growing importance in Local Positioning Systems (LPS). These architectures have special relevance in precision applications and indoor/outdoor navigation of automatic vehicles such as Automatic Ground Vehicles (AGVs) and Unmanned Aerial Vehicles (UAVs). The positioning error of these systems is conditioned by the algorithms used in the position calculation, the quality of the time measurements, and the sensor deployment of the signal receivers. Once the algorithms have been defined and the method to compute the time measurements has been selected, the only design criteria of the LPS is the distribution of the sensors in the three-dimensional space. This problem has proved to be NP-hard, and therefore a heuristic solution to the problem is recommended. In this paper, a genetic algorithm with the flexibility to be adapted to different scenarios and ground modelings is proposed. This algorithm is used to determine the best node localization in order to reduce the Cramér-Rao Lower Bound (CRLB) with a heteroscedastic noise consideration in each sensor of an Asynchronous Time Difference of Arrival (A-TDOA) architecture. The methodology proposed allows for the optimization of the 3D sensor deployment of a passive A-TDOA architecture, including ground modeling flexibility and heteroscedastic noise consideration with sequential iterations, and reducing the spatial discretization to achieve better results. Results show that optimization with 15% of elitism and a Tournament 3 selection strategy offers the best maximization for the algorithm.

Time difference of arrival (TDOA) positioning methods have experienced growing importance over the last few years due to their multiple applications in local positioning systems (LPSs). While five sensors are needed to determine an unequivocal three-dimensional position, systems with four nodes present two different solutions that cannot be discarded according to mathematical standards. In this paper, a new methodology to solve the 3D TDOA problems in a sensor network with four beacons is proposed. A confidence interval, which is defined in this paper as a sphere, is defined to use positioning algorithms with four different nodes. It is proven that the separation between solutions in the four-beacon TDOA problem allows the transformation of the problem into an analogous one in which more receivers are implied due to the geometric properties of the intersection of hyperboloids. The achievement of the distance between solutions needs the application of genetic algorithms in order to find an optimized sensor distribution. Results show that positioning algorithms can be used 96.7% of the time with total security in cases where vehicles travel at less than 25 m/s.