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Microstructure functional surface is widely used in an optical system because of its special micro-topological structure and particular physical properties. This paper presents a context-aware autonomously controlling method of micro-dots punching machine tool via establishing the digital twindriven cyber-physical system. Key enabling techniques on twinning of cyberspace and physical equipment are discussed. A dynamic adjustment model of piezoelectric ceramics for micro-dots punching is presented based on the high-precision online detection and control system. A novel staggered punching approach is proposed for improving the punching speed. A joint optimization model is proposed for coordinating micropunching system and staggered process. Context-aware autonomous adjusting of the system with errors analysis and compensations in the punching process is realized. Finally, a positioning accuracy of 2 µm and a high punching speed of 20-65 dots/s are achieved. This paper is expected to provide a new approach for incorporating smart-enabling techniques in the ultra-precision machining of microstructure arrays. INDEX TERMS Digital twin, cyber-physical systems, micro punching system, online joint optimization, autonomously controlling.

The mass personalization paradigm requires manufacturing enterprises to adapt to market changes quickly to meet customer demands. It also imposes higher requirements for designing intelligent production lines. Based on the digital twin (DT) technology, a rapid customized design method is proposed for developing new board-type furniture production lines. The DT has the characteristics of interactive virtual-reality mapping and fusion. It could provide design guidance and decision-support services in the design phase, yield the engineering analyzing ability to solve coupled problems, and finally generate the authoritative design scheme of the manufacturing system. A production line design platform is developed based on the DT model, which can parallelize the design process and reduce the design cycle. The parallel control between the physical world and digital space is achieved by establishing the DT network and perceiving the status of the physical equipment. Five key enabling technologies are introduced to provide the theoretical fundamentals for implementing the DT-based manufacturing system design approach. A board-type furniture production line is presented as a case study to verify the effectiveness of the method.

Large-scale personalization is becoming a reality. To ensure market competitiveness and economic benefits, enterprises require rapid response capability and flexible manufacturing operations. However, variant design and production line reconfiguration are complicated because it involves the commissioning, replacement, and adaptive integration of equipment and remodification of control systems. Herein, a digital twin-driven production line variant design is presented. As a new technology, the digital twin can realize the parallel control from the physical world to the digital world and accelerate the design process of the production line through a virtual–real linkage. Simultaneously, the actual production line can be simulated to verify the rationality of the design scheme and avoid cost wastage. Four key technologies are described in detail, and a production line variant design platform based on digital twin is built to support rapid production line variant design. Finally, experiments using a smartphone assembly line as an example are performed; the results demonstrate that the proposed method can realize production line variant design and increase production efficiency.