computers

Article
An Integrated Mobile Augmented Reality Digital Twin
Monitoring System
F. He 1 , S. K. Ong 2, * and A. Y. C. Nee 2

1 NUS Graduate School for Integrative Sciences and Engineering, National University of Singapore,
Singapore 119077, Singapore; [email protected]
2 Mechanical Engineering Department, National University of Singapore, 9 Engineering Drive 1,
Singapore 117576, Singapore; [email protected]
* Correspondence: [email protected]; Tel.: +65-65162222

Abstract: The increasing digitalization and advancement in information communication technologies

has greatly changed how humans interact with digital information. Nowadays, it is not sufficient
to only display relevant data in production activities, as the enormous amount of data generated
from smart devices can overwhelm operators without being fully utilized. Operators often require
extensive knowledge of the machines in use to make informed decisions during processes such as
maintenance and production. To enable novice operators to access such knowledge, it is important
to reinvent the way of interacting with digitally enhanced smart devices. In this research, a mobile
augmented reality remote monitoring system is proposed to help operators with low knowledge and
experience level comprehend digital twin data of a device and interact with the device. It analyses
both historic logs as well as real-time data through a cloud server and enriches 2D data with 3D
models and animations in the 3D physical space. A cloud-based machine learning algorithm is



applied to transform learned knowledge into live presentations on a mobile device for users to

 interact with. A scaled-down case study is conducted using a tower crane model to demonstrate the
Citation: He, F.; Ong, S.K.; Nee, potential benefits as well as implications when the system is deployed in industrial environments.
A.Y.C. An Integrated Mobile This user study verifies that the proposed solution yields consistent measurable improvements for
Augmented Reality Digital Twin novice users in human-device interaction that is statistically significant.
Monitoring System. Computers 2021,
10, 99. https://doi.org/10.3390/ Keywords: augmented reality; mobile augmented reality; human device interaction; human com-
computers10080099 puter interaction; digital twins; data visualization; mobile system

Academic Editor: Diego Borro

Received: 26 June 2021

1. Introduction
Accepted: 9 August 2021
Published: 12 August 2021
Digitalization has transformed traditional physical devices into smart connected
devices across all industries. Intelligent systems assembled from these smart devices
Publisher’s Note: MDPI stays neutral
are transforming home, city, and factory into smart home, smart city, and smart factory.
with regard to jurisdictional claims in
Technologies, such as Internet of Things (IoT), machine learning, and cloud computing
published maps and institutional affil- endow devices with communication capabilities and own intelligence. For a smart device,
iations. embedded IoT sensors collect massive amount of data that can be used for advanced
analytics to extract hidden knowledge [1,2]. However, as the human computer interaction
(HCI) scheme remains outdated in most circumstances, human operators can experience
an increased complexity and difficulty in comprehending and interacting with the digital
Copyright: © 2021 by the authors.
data. For example, in the manufacturing industry, manufacturing data from sensors and
Licensee MDPI, Basel, Switzerland.
production lines is often displayed as out-of-context digital numerals on inbuilt displays
This article is an open access article
or centralized terminals. This is difficult for novice users without sufficient training to
distributed under the terms and understand and can hinder the overall productivity. Thus, it is important to innovate on
conditions of the Creative Commons the ways that users interact with device data to improve information visibility.
Attribution (CC BY) license (https:// Digital twin (DT) is an emerging technology that has drawn great attention in the
creativecommons.org/licenses/by/ industry. It associates a digital entity to a physical asset to mirror or simulate physical
4.0/). characteristics and behaviors in real-time [3]. Inspired by the creation of DT for the

Computers 2021, 10, 99. https://doi.org/10.3390/computers10080099 https://www.mdpi.com/journal/computers

Computers 2021, 10, 99 2 of 20

manufacturing environment, it is possible to transform any smart device into a DT for

virtualization. Meanwhile, augmented reality (AR) is seen as an efficient interface to
enhance physical interaction by overlaying physical devices with digital information. The
rapid progress in mobile devices has made it possible to achieve online tracking and
recognition without the need to be tethered to a computer. In addition, the rise of internet-
based cloud computing has greatly enhanced the computation power available to a mobile
device that is connected to the Internet.
This research presents an integrated mobile AR DT monitoring system (ARDTMS)
that can help users better visualize and interact with the data produced using smart
devices. Through a personal mobile device, live data as well as executable knowledge
based on DT data can be received and interacted with remotely through the same interface.
Commercially available hardware and software solutions are utilized in the case study
to ensure that the system is implementable for any smart device. ARDTMS is novel as
the AR UI allows the users to select and visualize the types of data and simulations of
the DT of the respective physical twin that they are working on, as well as operate this
physical twin through controlling its virtual twin via the AR UI. In addition, ARDTMS
allows ubiquitous retrieval of information of and intuition interaction with the twinned
system to achieve both on-site and teleoperation of the twinned system based on analysis
and simulations from the DT system. A prototype for remote monitoring of a tower crane
is implemented. A user study is conducted to evaluate the performance of novice users
in a fault identification task when using the proposed system in comparison with using a
traditional data dashboard.

2. Related Works
Interacting with smart devices is not a new topic. Embedded interactions have been
implemented as efficient ways initially [4], while the mobile-based approach becomes
increasingly more popular since it can be used ubiquitously. Heun et al. [5] demonstrated
a system that integrates graphical user interface and tangible user interface to program
everyday objects into smarter objects with high flexibility. Mayer et al. [6] presented a
model-based interface description scheme to control a smart device with a mobile phone.
Yew et al. [7] designed a novel paradigm for interacting with smart objects via AR interface.
Most of the current work focuses on controlling smart devices and smart objects. However,
the enormous amount of data amassed creates a new challenge on HCI as it cannot be
read and understood easily by novice, sometimes even experienced, users. The interaction
between human and data associated with smart devices has a gap that needs to be filled.
DT is a powerful tool for extracting, analyzing, and displaying knowledge from
device data. The concept of DT can be dated back to NASA’s Apollo project in the late
1960s, during which two identical space vehicles were created and the one on Earth (called
‘the twin’) could mirror the operating condition for simulating the real-time behavior of
the one performing the mission. Later, the emergence of computer-aided design (CAD)
tools contributed to the rise of virtual design and simulation. Advancements in computer
technology has made real-time simulation a reality and the conceptual model of “a virtual,
digital representation equivalent to a physical product” or a “digital twin” was introduced
in 2003, which is regarded as the origin of DT [3]. Since then, DT has attracted more
attention along with the development of new information technologies, such as cloud and
edge computing, the IoT, big data, and artificial intelligence. It shows great potential in
the field of product design, manufacturing, production management and control, etc. [8,9].
With the increasing virtualization of resources and adoption of cloud services, DT is seen
as a pragmatic way for cyber–physical fusion. This creates new opportunity of enhancing
the HCI with human-in-the-loop considerations [10]. However, the current research on the
creation of DT has been focused primarily on technical features and lacks attention to end
user experience [11].
AR on the other hand has proven successful in improving the understanding of digital
information via natural interaction. AR systems have been researched and applied exten-
Computers 2021, 10, 99 3 of 20

sively in engineering analysis and simulation [12], as well as supporting robot control [13],
assembly [14–16], and manufacturing applications [17]. In addition to engineering, it has
good applications in medical, education, and entertainment [18]. Multiple modalities can
be implemented for improving the AR experience [19]. However, the lack of suitable hard-
ware and software usually constrains AR applications to fixed 2D screens or requires the
use of intrusive markers [20]. In recent years, AR research has seen a drastic improvement
due to four main developments [21]:
1. The pervasiveness of low-cost visual sensors, such as smartphone cameras, created
the foundation for AR consumerism.
2. The development in environmental perception algorithms, such as visual simultane-
ous localization and mapping (SLAM) and visual-inertia odometry (VIO), made it
easy for fusing virtual and reality [22,23].
3. The availability of consumer-level AR displays based on advances in optics and
mobile processors.
4. The maturity of multimedia techniques has enriched the content and interaction styles
of AR applications [24,25].
Even though many conceptual frameworks for DT systems have been proposed, few
were implemented. This is mainly due to the challenges in high-fidelity modelling and
simulation, life-cycle data integration and fusion, connection and interconnection [26].
Simulating real-time behavior on a high-fidelity virtual model is computationally costly.
A few researches have been reported the integration of DT with AR [27–30]. Schroeder
et al. [27] developed an AR user interface (UI) for data visualization of a DT system. Rabah
et al. [28] used DT and AR for predictive maintenance. Zhu et al. [29] reported the use of
AR for customizable visualization of DT data depending on the virtual objects selected.
Liu et al. [30] used AR to provide real-time monitoring of the machining processes on a
CNC machine to the users, with data and simulation from the DT machining system. AR
has been used mainly as a visualization tool for monitoring the physical twins in these
reported work. When integrating DT with AR, the rendering of visual content adds load to
the computation resource. This makes it even harder to integrate AR and DT on a mobile
device. To work around these technical limitations, in this research, DT data processing is
offloaded to a cloud server, and only AR rendering of the computed result is performed
on the mobile device. Utilizing DT data, AR can help users understand the operating
conditions more efficiently. When used remotely, it can reduce cost and time of physical
travel on-site for diagnosis. For a smart device that is malfunctioning, AR can provide an
intuitive alternative to traditional digital numerals on the screen. Overall, the integrated
system should allow ubiquitous retrieval of information and intuitive interaction with the
smart devices.

3. System Framework
Figure 1 presents the system architecture for ARDTMS, where a user interacts with the
DT through an AR user interface; the solid lines are data and information flows, and the
dashed lines are interaction and visualization via the AR interface. As the programming of
both DT and AR applications presumes a deep knowledge of the underlying technology,
the goal of such a framework is to simplify the development of the integrated system and
focus on defining the interfaces across each module. As shown in Figure 1, the DT passes
the learned knowledge onto the AR device, which will present the information, and a
user interacts through the same AR interface to control the physical operation and virtual
simulation. The framework is formulated based on the implementation of a model tower
crane case study, but it can be adapted for an industrial machine by replacing the input
data, digital model, as well as the computing engines.
 and can mirror its status in the virtual space to display the real-time changes of the
equipment under monitoring. The “live” model can also help users comprehend
operating conditions based on knowledge acquired from the historical data. Various
computation processes can be implemented in the virtual space to integrate advanced
Computers 2021, 10, 99 functions, such as energy consumption analysis and inventory management.4 ofThe 20
computed results will be used for decision support and event identification that can be
visualized using the AR user interface.

Figure 1. The system architecture of ARDTMS.

Figure 1. The system architecture of ARDTMS.
The physical device exists in the physical space and has embedded sensors with
The AR user interface is a software application installed on a mobile device, such as
networking capabilities through Wi-Fi or Ethernet connection. In addition, devices gen-
a smartphone, tablet, or head-mounted display. The mobility of the device ensures that
erally have built-in information systems that keep record of the usage information (logs).
the application
Collecting can aid
data from a user
both ubiquitously.
sensors Theinformation
and built-in learned knowledge
systems from the DT
provides thewill be
basic
presented to the user by augmenting or placing
infrastructure required to apply DT to the physical device. a complete digital model at the user’s
current
Next,location. In the case
the collected data study, the and
is filtered AR interface
stored inenables remote storage.
a cloud-based process control to help
The Firebase
the user respond to disruptions in time. In the following sections, the method
Real-time Database and Microsoft Azure are used in the case study to provide cloud storage to apply the
elements in the ARDTMS framework for general smart devices will be discussed
and computing service, respectively. In addition to the physical data, the DT requires a in detail.
CAD model reflecting the geometry, physics, and behavior of the physical device. The
3.1. Prerequisite
fidelity of the modelof the
canPhysical
vary based Device
on the level-of-details required by the use case. With
Data is the
data collected enabler
from for smart
the physical devices,
device, theand thevirtual
static data indevice
a smart environment
becomes “live” can
andcome
can
from different
mirror its statussources, including
in the virtual spacethetodevice,
displayhuman, as wellchanges
the real-time as the environment.
of the equipmentIn the
under monitoring. The “live” model can also help users comprehend operating conditions
based on knowledge acquired from the historical data. Various computation processes
can be implemented in the virtual space to integrate advanced functions, such as energy
consumption analysis and inventory management. The computed results will be used for
decision support and event identification that can be visualized using the AR user interface.
The AR user interface is a software application installed on a mobile device, such as
a smartphone, tablet, or head-mounted display. The mobility of the device ensures that
the application can aid a user ubiquitously. The learned knowledge from the DT will be
presented to the user by augmenting or placing a complete digital model at the user’s
current location. In the case study, the AR interface enables remote process control to help
Computers 2021, 10, 99 5 of 20

the user respond to disruptions in time. In the following sections, the method to apply the
elements in the ARDTMS framework for general smart devices will be discussed in detail.

3.1. Prerequisite of the Physical Device

Data is the enabler for smart devices, and the data in a smart environment can come
from different sources, including the device, human, as well as the environment. In the
scope of this work, the DT data comes from the physical device itself, and is collected using
wired and wireless sensors and inbuilt information system that records the operating status
and the interaction with users. Some examples of useful DT data include energy usage,
machine settings, temperatures, error codes or alerts, log files, etc. The data collected is
divided into two categories, namely, real-time data and historical data.

3.1.1. Real-Time Data Collection

Real-time data relating to a specific device makes it possible to continuously measure,
monitor, and report the current operating status. It provides the user with the ability to
gain visibility of the machine, so that it is possible to assess whether an asset is operational
and tracks the basic performance metrics. Remote monitoring using IoT enhances this
ability even when a user is not physically located close to the machine, or the condition of
the machine is not easily understood even if the user is located right next to the machine.
Traditionally, the data is presented through comprehensive real-time dashboards. This
information can improve equipment uptime, reduce service visits, and improve on first
time fix rate.
The real-time data comes from different sources, including smart sensors communicat-
ing to a networking gateway through wired connection, such as RS485, Ethernet, as well
as wireless connections, such as radio frequency identification (RFID), Bluetooth, 4G, 5G,
etc. [31]. Essentially the IoT technology with different protocols allows real-time data to be
passed to smart terminals, such as PCs (personal computers) and tablets easily through
SDKs (software development kits) or APIs (application programming interfaces).
Modern device manufacturers have implemented the necessary tools to support the
infrastructure of smart initiatives. However, users often find that the data is only accessible
through the inbuilt LED (laser emitting diode) or LCD (liquid crystal display) displays,
or dedicated software. The digital numerals show limited information, and the more
comprehensive dashboard requires greater cognitive attention. The non-standard nature of
these media can be hard to navigate and confusing for a novice user to grasp the essence
of the data. By identifying user and device condition, it is envisaged that visualizing
contextual real-time data with ARDTMS can reduce the cognitive load and assist the user
remotely.

3.1.2. Historical Data Logging

Historical data generally refers to system features and functionalities used by end-
users along with the associated metadata, such as time and data input [32]. Device in-
formation systems record and store this data in the form of data logs to understand the
end-user interaction with the device. Real-time sensory data are also recorded over a longer
time-stamp to enable analytics to identify operating events. The sampling frequency is
usually kept low and each data type is allocated a fixed amount of storage space. Once
the number of data entries exceed the limit, older data will be deleted or summarized into
a single document with reduced granularity so that it can be compressed for long-term
storage [33].
Historical data can be structured (digits, symbols, and tables, etc.), semi-structured
(trees, graphs, etc.), and unstructured (logs, audios, videos, etc.) [34]. Currently, there are
no effective ways to analyze unstructured data. Semi-structured data does not conform to
strict standards. Extensible Markup Language (XML) is a typical example that contains
user-defined data tags, which make them machine readable. In this work, the historical
data are structured tabular data found in spreadsheets or relational databases. The data
Computers 2021, 10, 99 6 of 20

needs to be filtered to fill missing values, remove duplicates and garbage, and format data
entries. This is the prerequisite that comprehensive knowledge can be derived from a large
quantity of dynamic and ambiguous raw data.

3.2. Building the Virtual Device

The DT of a physical product acts as its virtual representation. The virtual model
includes the geometric entities and the rules and behaviors, such as material properties
and machine functions [26]. Various computation engines can be integrated in the digital
space to support simulation, evaluation, and prediction.

3.2.1. Digital Model of the Device

The geometric model is the fundamental of a DT and is commonly built with CAD
software, such as SolidWorks, 3D MAX, AutoCAD, CATIA, etc. The three-dimensional (3D)
model defines the shape, size, position, and assembly relations of the machine components.
As modern equipment manufacturers constructed the CAD model before manufacturing
the equipment, the CAD model is generally available upon request by the end-users.
The fidelity of the model can be improved by adding physical properties (hardness,
surface roughness, tolerance, density, etc.). This can be useful for analyzing the physical
phenomena, such as deformation, cracking, and corrosion, according to the use case of
the DT. A product designer may require the full knowledge of the physical properties
of the material and the capabilities of the machine tool, while the end-user may only be
interested in the finished product and less so about the properties of the machine. A higher
fidelity will demand higher computation cost. The level of details of the digital model
is also limited by the bandwidth of the wireless communication to the user interface for
ARDTMS. The user should assess the most critical metrics for the application to reduce
computation cost.

3.2.2. Computation Engine

Engineering simulation and big data analytics can be highly demanding on computa-
tion resource. With the emergence of cloud and edge computing, analytics and simulation
on the virtual model can be offloaded to a cloud or edge server instead of being tethered
to a local server. The greater storage capacity and higher computing power along with
advances in fast algorithms make real-time analysis possible and accessible to more users
than ever before. Finite element analysis (FEA) can be performed for variation simulation
to understand bending and deformation of products [35]. Predictive analytics can be
applied on greater datasets with regression and machine learning techniques, instead of
deriving statistical significance from small samples conventionally [34]. Combining both
real-time and historical data, the system can provide diagnostic scenarios that yield various
levels of performance. By identifying fields that best explain the outcome, the system can
continuously improve the predictive internal logic of the model for further optimization.

3.3. The AR User Interface

The AR user interface is a software application installed on a mobile device to ensure
that the application can aid a user ubiquitously. The AR interface presents the learned
knowledge from the DT to the user by augmenting or placing a complete digital model at
the user’s current location. This AR interface enables remote process control to help the
user respond to disruptions in time.

3.3.1. AR Interface Development

The rapid advancement in both hardware and software has enabled building AR
applications on mobile and wearable devices. HMDs like Microsoft HoloLens and Vuzix
provide AR experience while freeing up the hands of a user, which is favorable for main-
tenance and assembly operations. Smartphones or tablets, on the other hand, provide
a cheaper alternative and is more comfortable to a user, and it is more conducive for
Computers 2021, 10, 99 7 of 20

prolonged monitoring and assistive tasks. Development tools, such as ARKit, ARCore, and
Vuforia, are most popular due to the growing number of Android and iOS developers [36].
Although only available on iOS platform, ARKit supports marker-less plane tracking, 3D
object tracking, as well as multiuser sharable experience. Its tracking capability is also
more reliable due to better software-hardware calibration for the iOS devices, which are
more standardized than the vast variety of Android devices. Thus, ARKit is chosen for the
prototype of ARDTMS.

3.3.2. Interacting through AR Interface

The networking capability of the system allows real-time two-way interaction be-
tween a user and the device through the AR interface. On one hand, real-time data and
derived knowledge from the virtual device could be presented through the AR interface
as requested. Since the analysis is computed in the cloud, only outputs such as utility
consumption, production statistics, and forward simulation will be presented for higher
relevancy and less distraction. On the other hand, the user can input commands to control
the device. As the system is implemented on a smartphone with ARKit, the system adopts
a point-and-click mechanism. Virtual buttons allow for remote device controls. Live data is
linked to corresponding sensor locations and the user can move the data visualization to
find optimum view to observe relevant information.
ARDTMS supports the monitoring of a physical device both locally and remotely.
When a user is physically located next to the device, the system overlays the virtual model
of the device onto the physical device partially to highlight regions of interest or prompt
assistive information. Since the user can interact with the device through the physical
interface, ARDTMS mainly complements the physical functionalities through the AR
interface in this situation. When the user is located remotely from the physical device, the
system can mirror the current status of the physical device by augmenting the full virtual
model in the user’s current physical space. This intuitive representation helps the user to
interpret data as if he/she is interacting with the physical device.

4. Case Study
ARDTMS is demonstrated through the monitoring of the operating status of a scaled-
down industrial prototype of a tower crane model. The implementation process helps to
investigate the benefits, challenges, and limitations of the proposed system in detail. A user
study is conducted to evaluate the advantages and effectiveness of the proposed system
against the live data dashboard. The user study aims to verify whether the integrated sys-
tem yields measurable improvement during the HCI process for users who are unfamiliar
with a particular process.
One of the greatest challenges in industrial tower crane operations is to understand
the wind load. In the prototype, the tower crane will operate in a laboratory environment
under different simulated wind conditions. This aims to simulate the situation that a crane
operator often faces. Although there are general safety guidelines based on measured
wind speed from anemometers, the varying characteristics of the load, the boom, and
even the site can be hard to gauge. In addition, nonlinearity exists in the system as well
as the dynamics coupled in the random movement caused by gust of winds making it
difficult to develop a precise model to describe the system. This makes the model-based
approach, which requires structural parameters including elastic modulus, density, cross-
sectional area, mass, etc., of all parts of the tower crane, difficult to achieve. Although no
precise mathematical model is available, a data-driven method can help with the operation
monitoring process.
Normally, a crane operator will need to judge whether the lifting task can be pro-
ceeded or not based on his/her own experience and knowledge. Comprehensive live
data dashboard is used, from which operating trends can be read to identify anomalies.
However, this can be difficult for novice operators, which could result in fatal accidents. To
help novice operators, this case study aims to assist operators to understand the current
Computers 2021, 10, 99 8 of 20

operating conditions and avoid dangerous operations with real-time data, and knowledge
learned from historical data as well as previous operators, presented through the AR
interface. Figure 2 shows the overview of the implementation of the monitoring system.

Figure 2. The implemented ARDTMS framework for tower crane monitoring.

4.1. Physical Asset Hardware Setup

The tower crane used in prototyping the application has two inbuilt DC (direct current)
motors, allowing horizontal rotation and hoisting of loads. To transform it into a smart
device, it is enhanced with additional sensors as shown in Figure 3, including infrared
proximity sensors attached to the end of the jib to measure the load distance, and two Flexi-
force pressure sensors placed under the base to measure the pressure distribution under
different conditions. An Arduino Uno connected with the ESP8266 thing development
board is attached to the mast as the sensing module. For the case study, a second ESP8226
thing development board as the control module is attached to replace the wired controller
in order to achieve remote and automated control of the tower crane operations. It “listens”
to a control code from the cloud database to trigger reaction of the physical tower crane.

4.1.1. Data Collection Module

The proximity sensor and two load sensors are connected to an Arduino Uno analog
input pin for data collection and pre-processing. The raw data is measured as voltage
level between 0 to 5 volts at 250 Hz frequency. This is converted using a 10-bit analog
to digital converter into integer values between 0 and 1023. Next, each sensory data is
smoothed by taking the average of 50 measurements to reduce noise. Finally, the smoothed
data is multiplied by a pre-determined conversion factor to calculate the measurements in
distance (cm) and pressure (Pa).
Computers 2021, 10, 99 9 of 20

Figure 3. Hardware setup of the tower crane prototype.

4.1.2. Transmission Cloud Gateway

The Arduino sends the collected sensory data to an ESP8266 thing development board
through the serial port. As measured, the serial communication takes 37 ms. For the case of
monitoring of tower crane status while maintaining moderate communication bandwidth,
the average measurements are programmed to be transmitted every 0.5 s. This ensures a
reliable data transmission rate between the sensors and the cloud gateway. Every time an
averaged measurement is taken, the cloud gateway will convert the readings into JSON
(JavaScript Object Notation) format and add in the timestamp. A sample data entry has the
following fields as shown in Table 1.

Table 1. Sample formatted data fields.

Fields Sample Value Description

Distance 57.7 Distance from load to the jib
force1 31.17 Pressure at first foot of the base
force2 31.65 Pressure at second foot of the base
Unix time in milliseconds, synced from Network
epochTime 1562900362608 Time Protocol (NTP) and recorded as timestamp
for the current reading
Milliseconds passed since the last updated reading.
deltatime 697
Recorded from the Arduino’s inbuilt clock

4.2. Cyber Space Development

The cyber space mainly handles data storage and processing. It also relays user
command in the form of control code to manipulate the physical tower crane. The cloud
database is tasked to notify and sync changes to any subscribed clients. The computation
engine is for learning from historical data and use the learned knowledge to assist the user
in comprehending real-time operating condition.
Computers 2021, 10, 99 10 of 20

4.2.1. Syncing through Database

The ESP8266 units serving as the cloud gateway as well as the one as control module
are both connected to the cloud database. Data is synced across all clients, including both
the dashboard as well as ARDTMS system in real-time. This is achieved through WebSock-
ets on both the server and the client side. It opens a two-way interactive communication
session so that clients can send messages to the server and receive event-driven responses
without having to poll the server for a reply. In the case study, the solution provided using
the Firebase Real-time Database is implemented for hosting the sensory data and control
code.
In the case of the Firebase Real-time Database, clients are connected to the database
and will maintain an open bidirectional connection via WebSockets. Next, if any client
pushes data to the database, it will be triggered to inform all the connected clients that
it has been changed by sending them the newly saved data. In the prototype, the cloud
gateway will push formatted data to the real-time database every 0.5 s. Upon receiving the
update, the database will notify connected clients (live dashboard and AR devices) about
the change and send them the new data. The network latency from database to client is
between 200 ms to 500 ms under tested conditions (all device connected to internet via
Wi-Fi). This latency can be higher or lower depending on the network condition. Overall,
the live data is collected at 2 Hz frequency with a latency of around 1 s.

4.2.2. Historical Data Hosting

Each simulated value will be stored in the historical database to allow backward
checking to understand how the issue arises and help technician drill down the analysis.
The Firebase Real-time Database implements a NoSQL (Not Only Structured Query Lan-
guage) database, which is non-relational. This makes it superior in frequently updating
and processing high-volume, real-time data at great speed. As shown in Figure 4, there are
five first level nodes for the JSON object. The CRANE_CONTROLLER is the control code,
which is updated by the client and read by the physical tower crane control module. The
value ranges from 0–4, representing idle, anti-clockwise rotation, clockwise rotation, lifting,
and dropping motions. The LED_STATUS is a string value that represents if the sensing
module is turned “on” or “off”. The SAMPLING_RATE is a debugging parameter that has
two states, “H” and “L” for high and low sample rates. The high rate is 2 Hz and the low
rate is 0.5 Hz, which is predefined while programming the sensing module. The “lastData”
field is the most recently read data information that is immediately passed on to the clients.
Note that a “state” field is added which value is taken from the CRANE_CONTROLLER.
This is helpful in training the machine learning module as the sensor data have distinct
characteristics over different operating states. A new entry is added at the same time the
“lastData” is updated to the “logs”, which contains all the historical data that has been
recorded. A unique ID (random string) is automatically added in Firebase for efficient data
retrieval.

4.2.3. Building Computation Engine

Based on initial observations, the external wind condition will cause irregular fluctua-
tions in the sensory data time series. Although a direct relationship between the load, the
wind, and the operating state is difficult to obtain, a machine learning-based classification
engine can make use of the historical knowledge in a more efficient way. The learning and
testing are based on data in the idle state since the operation should not be started if the
idle state is already in a dangerous condition.
First, the raw sensory data is preprocessed by grouping all values between every five
seconds (9–10 data entries due to networking latency). A rolling standard deviation is
calculated for each sensor data to construct new features for machine learning. The latest
time-stamp is used as the only time-stamp for the new congregated data. The state with the
highest number of counts is chosen as the congregated state. The “deltatime” is neglected
Computers 2021, 10, 99 11 of 20

as it does not contribute to the learning engine. After the preprocessing, the training data
has 301 rows of data operating at the healthy state.

Figure 4. Database entries and values.

Next, a similarity-based one-class classification approach is implemented in this

study [37]. Training historical data consists of 301 rows of filtered data from the three
sensors. The tower crane was operated without any external wind load to generate
historical data. The historical data is fed into a One-Class Support Vector Machine model
for anomaly detection. The model infers the properties of normal cases and predicts if
the new input is unlike the normal examples. It uses a radial basis kernel and has two
parameters, namely η and ε. η corresponds to the nu-property that represents the upper
bound on the fraction of outliers. ε defines the stopping tolerance, which leads the trainer
to stop iteration when the value is exceeded. A Tune Model Hyperparameters module is
then connected to sweep the parameters to find the optimal setting. The solution reaches
optima when η = 0.1 and ε = 0.01.
Figure 5 shows the implementation of the computation black box. The data-driven ap-
proach provides a probabilistic estimation of the fault condition rather than a deterministic
result. In fact, the lack of validation dataset makes it difficult to assess the precision as the
model may cause false negatives. In addition, the model should be refined continuously
with new additional data from real life use cases for better accuracy. Nevertheless, the
computation engine serves as an illustration tool to showcase the use of the proposed
system. It outputs a confidence score between 0 and 1, which can be regarded as the
operating risk.

4.3. User Interaction

The AR visualization is one of the main contributions of the proposed system; the AR
user interface provides visualization of the analyzed data and states directly on a physical
twin. As compared with commonly used live data dashboards, AR visualization of device
data is more intuitive and effective in assisting novice users. This section will demonstrate
how the integrated system can be used to assist the human–device interaction (HDI) during
a remote monitoring scenario. A live data dashboard is also developed as a benchmark
in the user study to evaluate the performance of the proposed system so as to determine
whether ARDTMS is superior to the live data dashboard.
Computers 2021, 10, 99 12 of 20

Figure 5. The training workflow for fault detection.

4.3.1. Dashboard View

The live data dashboard is a web-based application that plots the historical data in the
last 3 min, as shown in Figure 6. It can be accessed from multiple devices simultaneously.
The blue line on the left is the reading from the proximity sensor. The orange and green
lines are plotted in the same graph to show the comparison of the two pressure sensors. The
lifting and dropping operations can be read from the distance graph. Some disturbances can
be seen between 15:12 and 15:13. A level drop of Force1 can also be observed immediately
after 15:14. An expert may try to assess the operating condition from the live data graph.
However, it is difficult for users with no experience to determine whether the fluctuation is
abnormal or not.

Figure 6. Real-time dashboard showing data over last 3 min; (left): proximity sensor readings, (right): pressure sensors
readings.
Computers 2021, 10, 99 13 of 20

4.3.2. Mobile AR Client

The UI of the mobile client is shown in Figure 7. Since the system has to maintain
continuous networking connection to retrieve live data, the UI design follows the principle
to minimize active elements to reduce loading of the mobile client, which has limited
computing and battery resource. The top right corner displays the current latency of
passing sensory data from the cloud gateway to the client device. At bottom right corner,
there are four buttons that allow for the remote control of the physical tower crane, and a
panel indicates the current operating mode. In the main view, the DT model can rotate and
move the hook as the physical device does. The rotating and hoisting speed are calibrated
to be the same as that of the physical tower crane. The sensor node annotations are added
to indicate the readings with links to the embedded positions. They are linked to the
database URL (Uniform Resource Locator) where real-time data is updated constantly.

Figure 7. The mobile user interface and side-by-side comparison of DT and the physical tower crane.

Using the proposed system, when the user is in a remote location, he/she can access
the DT model in his/her current environment to help diagnose remotely before on-site
action is taken. When the computation engine receives a set of sensor readings that
produces a risk score higher than 50%, a warning alert is sent to the technician’s personal
device. The risk level is shown through the UI panel, and the system continues to process
the incoming data. If the risk increases and exceeds 70%, the system determines that the
condition is dangerous and will suspend all control functions to prevent any potential
damage.

5. User Study
A user study was conducted to validate whether the integrated system yields mea-
surable improvement during the human–device interaction process for users that are
unfamiliar with a particular process. This is achieved through a qualitative and quantita-
tive evaluation of the advantages and effectiveness when providing assistance to the users
through the proposed system against the traditional live data dashboard. In the current
procedure, a remote operator would monitor the tower crane operation via the variation of
data displayed in the live data dashboard. However, it is difficult for a novice user without
extensive knowledge on the tower crane operation to identify anomaly by looking at the
data. To eliminate this difficulty, ARDTMS takes over the data comprehension based on
the historical knowledge. A total of 20 students from mechanical and civil engineering
disciplines are invited to participate in the study. They are divided evenly into the control
group (A) and the experimental group (B). Each individual from the control group is paired
with another from the experimental group. The former will monitor through the live
data dashboard while the latter will monitor through the AR interface simultaneously.
A disruptive event will be introduced during the monitoring process and the users are
expected to respond to the event.
The following hypotheses are made prior to conducting the study:
Computers 2021, 10, 99 14 of 20

1. Users using ARDTMS will respond faster to events as compared to users using the
live data dashboard users as they have assistance from a holistic and single view that
focuses on user attention;
2. Users using ARDTMS will perform more consistently at a similar level than users
using the live data dashboard as they are assisted by intuitive AR stimuli;
3. The ARDTMS system can reduce user errors as the historical knowledge that is taken
into account to provide AR assistance is more reliable than the primitive personal
judgement.

5.1. Experiment Design

The user study is conducted through a pre-test and post-test evaluation of usability
measures rated by the users, and performance measure recorded by the researcher [38]. As
shown in the appendix, before the test, all participants were asked to rate their knowledge
of the tower crane and its operation. Their own subject rating is complemented with
objective assessment by asking them to fill in the name of the main parts of the tower crane.
This is to verify that all participants are novice users with similar expertise level. Next,
they were briefed on the UI of respective monitoring systems. Without training, the two
users, one each from the control group and the experimental group, will start monitor
the data stream on their own at a remote location without direct view of the physical
tower crane. They were asked to signal once they observe any anomaly. Meanwhile, a
swinging standing fan is turned on to generate wind towards the tower crane. The response
time of each participant is recorded as the key benchmark for evaluation. In the post-test
session, the participants are first asked to describe the anomaly that is observed during
the experiment. The correctness of their answers is used to as supplementary measures
to assess the effectiveness of the system. Next, they filled up a questionnaire including
a set of five-point Likert questions. This aims to provide a qualitative feedback on each
system in terms of its mobility of interactive medium, intuitiveness of the UI, efficiency
of interaction, and overall satisfaction. In the end, the questionnaire requires the user to
provide comments and suggestions on the respective systems.

5.2. Sample Selection

As the user study aims to evaluate a novice user learning process, participants should
have basic awareness of the use case, but not the expert level experience. The selected
participants are university students with mechanical or civil engineering background. All
the participants have basic understanding of the tower crane structure but have no hands-
on experience or in-depth understanding of tower crane operations. This is evaluated in
the pre-test questionnaires to make sure the participants are indeed novice users.
The sample size of 20 students (10 paired groups) is determined through an iterative
process [39]. The null hypothesis for the quantitative performance test is that the true
mean difference of a user’s response time to critical event when using the proposed system
comparing with using traditional dashboard is zero. For this paired t-test, a confidence level
of 95% is targeted. The test began with five test groups based on the five-user assumption,
which assumes that five participants suffice for usability testing, and will increase by five
groups until p-value is below 0.001 to show statistical significance, or the null hypothesis is
proven true [40]. Extreme outliers will be treated separately so that the sample data for
calculation will follow an approximate normal distribution [39].

5.3. Usability Measures

The common usability measures in HDI research include effectiveness, efficiency, and
satisfaction [38]. In this study, the recorded response time provides objective assessment of
the effectiveness aspect of the usability, while the efficiency and satisfaction measures are
assessed subjectively based on user ratings. In addition, the users were asked to rate the
mobility and intuitiveness of the systems as these two measures are targeted in the system
design. The subjective rating is scored between 1–5, where 5 means “most positive” and 1
Computers 2021, 10, 99 15 of 20

means “most negative”. The mean value of the ratings is used to compare each aspect of
the proposed solution to the traditional dashboard.

5.4. Result Discussion

The pre-test questions show that all participants have minimum knowledge of the
tower crane (none or beginner). The ratings and response time are summarized in Table 2.
In the first five groups, the response time for group 5A is an invalid extreme value, thus
the user study is continued with an additional five user groups.

Table 2. Sample formatted data fields.

Response
Group Mobility Intuitiveness Efficiency Satisfaction
Time (s)
A B A B A B A B A B
1 2 5 1 5 3 4 2 5 6.6 4.1
2 5 4 2 4 4 5 3 4 8.6 4.8
3 5 5 4 2 4 4 4 4 9.0 5.0
4 5 4 3 4 3 4 3 4 7.38 5.2
5 2 4 3 5 3 4 4 4 Inf 7.0
6 2 4 2 4 1 3 2 4 Inf 5.0
7 4 5 4 5 5 5 4 5 Inf 5.5
8 5 5 5 5 5 5 5 5 6.6 4.7
9 4 4 3 5 4 5 3 4 2.0 4.7
10 5 4 4 3 5 4 5 5 9.0 4.7

5.4.1. Response Time Evaluation

The goal of response time evaluation is to determine which monitoring system allows
users to react better and quicker to abnormal operating conditions. By measuring the
response time, the evaluation aims to validate experimentally that the ARDTMS system
produces a faster reaction time that is statistically significant through a paired t-test.
In the response time test, almost all participants using ARDTMS (B) outperformed
the users who used the live data dashboard (A), except for one live data dashboard user in
group 9, who responded immediately at first sight of a signal level change. The response
time data for this user is marked as an outlier and excluded in the following statistics since
this user reacted based on a wrong criterion. In addition, three live data dashboard users
did not report any anomaly as they perceived the disturbance as “is not significant”. They
are excluded so that a meaningful average improvement in response time can be analyzed
in a paired t-test.
In all other groups, the response of the users of ARDTMS to the anomaly is 38.8%
faster on average. The mean absolute improvement in response time is d = 3.1 s with a
standard deviation (SD) of s_d = 1.03. Using paired t-test, t(5) = 7.4, p = 0.0004. These
data show that there is a significant statistical difference between the response time of
users these two interfaces despite the small sample size. Thus, it is sufficient to prove
that the ARDTMS system yields benefits in improving the user response time to abnormal
operating conditions for the novice users. It is worth noting that although groups 5, 6, and
7 are not included in the quantitative evaluation, the reaction time from these users proves
the hypothesis that the users of ARDTMS systems react quicker to anomaly as the live data
dashboard users do not react at all.
In addition to a shorter reaction time, the ARDTMS users have a lower variation
in the response time (SD = 0.77 s) comparing to the dashboard users (SD = 1.14 s). This
is because for the dashboard users, they can have vastly different individual opinions
regarding the definition of anomaly when observing the live data plot. As for the ARDTMS
users, the system uses historical data to compute and trigger the alert to notify users.
The cognitive process of identifying anomaly is offloaded to the computation engine. As
Computers 2021, 10, 99 16 of 20

a result, ARDTMS monitoring yields a more consistent improvement regardless of the

individual differences among the users.

5.4.2. Error Analysis

Novice users are more prone to errors due to lack of experience. The empirical user
study is designed to be an identification task, and the aim is to determine the correctness of
the users’ interpretation of the operating conditions. Errors in this experiment are defined
as instances when a user reports an anomaly before the disturbance is introduced (group
9A) or does not react long after the disturbance has been introduced (groups 5A, 6A,
and 7A). For group 9A, this is caused by overreaction to incorrect stimuli. In industrial
scenario such as on the manufacturing shop floor, overreaction from operators can lead to
unwanted increase of downtime and reduction in productivity. For the rest of the error
cases, the novice users’ non-reaction indicates the inability to identify stimuli that relate to
the anomaly. In industrial production scenario, this can result in hazardous conditions to
both the equipment and operators.
There are more error cases in the dashboard group. Despite the limited sample size,
4 out of 10 user errors are observed, including both over-reaction and non-reaction. On
the other hand, all ARDTMS users are able to respond when anomaly occurs. Since the
AR alert is sufficiently intuitive to draw immediate attention from the users, the accuracy
of user reaction is a direct reflection of the computation model accuracy, which is trained
and can be improved continuously with historical data. The users should be aware that the
computation backend is a built with a statistical model. In case of anomaly identification,
generally the threshold should be lowered to increase recall and minimize false negatives
because an actual fault can result in severe damage to production activities, while the
interruption by false positive cases is more recoverable. Ideally, the model should capture
all error cases with as little false positive cases as possible.

5.4.3. Qualitative Ratings Analysis

The qualitative Likert ratings was conducted for the users to evaluate their experience
with the monitoring systems. Positive feedback has been observed as the ARDTMS users
have a higher rating in the qualitative test than the dashboard users, as shown in Figure 8.
Additionally, the interquartile range of the ratings is smaller for the ARDTMS group, show-
ing that novice users are generally very receptive to this monitoring approach. Regardless
of the individual differences between users, ARDTMS users tend to give ratings at a similar
level because their experiences when using the system is similar. This shows that ARDTMS
has an equalization effect on not only the user performance in terms of smaller variation in
response time, but also the user experience among different users consistently. It proves
that the ARDTMS can bring more novice users to an acceptable performance, thus it is
more generalizable than dashboard monitoring among novice users.
The following agree-disagree questions required the users to provide opinions on their
own performance during the anomaly detection. First, all ARDTMS users strongly agreed
or agreed that the system can help them understand the operating condition without
expert help, while only 60% of the dashboard users are similarly confident. This is aligned
with users’ quantitative ratings result. Next, three users agreed and four strongly agreed
that the ARDTMS system provides just enough information. As for the dashboard users,
the numbers are 6 and 1 for agreed and strongly agreed, respectively. This is because
UI of ARDTMS was carefully designed with minimum assistive content due to limited
computation and battery resource on the mobile device. On the other hand, the dashboard
plots the live data continuously and requires a user’s constant attention. In prolonged
usage, this can result in fatigue and loss of focus, while 3D AR visualization can engage
users better as compared with numerals and abstract illustrations.
Computers 2021, 10, 99 17 of 20

Figure 8. Results of the qualitative evaluation.

Lastly, the ARDTMS users were asked to rate the remote control function via the
mobile interface using the same four dimensions. Through ARDTMS, users were able to
control the tower crane operation in real-time from their mobile device; they could also
view the motion through the AR model, which fully reflects the operation of the physical
tower crane. The ratings show positive scores (above 3) in all aspects, including mobility,
intuitiveness, mobility, and satisfaction for the remote control function. This is because the
immersive visualization provides immediate feedback that can help users take appropriate
actions based on the monitoring result.

5.4.4. User Comments and Suggestions

The user survey concluded with open-ended comments and suggestions. In the
comments and suggestions, three dashboard users believed that the dashboard was not
intuitive and lacks reference for dangerous operating conditions. The lack of reference
for dangerous operating conditions is because there is no definitive simulation approach
nor single level of reference that can be used to determine anomaly. This shows that some
novice users have difficulty in understanding the dashboard monitoring system and would
take significant cognitive load during the anomaly identification task.
Two ARDTMS users commented that the control function was not smooth due to
network delay. This is caused by the communication to the cloud services as well as the pro-
cessing speed of the Arduino unit. The latency issue can be improved by using industrial
grade microprocessors and using dedicated server from the cloud service provider. How-
ever, further research is necessary to understand the optimum content-to-bandwidth ratio
based on the use case so that the users will not be overloaded with redundant information.
One ARDTMS user argued that the live data display was not helpful as he only
responded to the risk level alert and DT model color change. This shows a gap between
the design and utilization of user-created annotation and the monitoring system. Other
users agreed that the annotation helps them to understand which part of the system has
the most likelihood of causing the issue. This contradiction shows that the usefulness of
raw sensory data could be depended on the expertise level of the user receiving the data.
One user suggested further improving the ARDTMS by adding in an external view of
the tower crane surroundings. This can be achieved via additional image capturing device
mounted on the tower crane. However, this would greatly increase the networking load. In
an industrial application, additional sensory device needs to be justified with a cost-benefit
analysis. Another user noted the dashboard and ARDTMS could complement each other
as one gives a direct feedback based on learned knowledge, while the other is better at
presenting historical trends for further detailed analysis. To merge the dashboard into
Computers 2021, 10, 99 18 of 20

ARDTMS, a sophisticated adaptive UI design is necessary so that an embedded dashboard

can be integrated into ARDTMS. The dashboard should only emerge during diagnostics so
that it will not distract user attention most of the time.
Lastly, one ARDTMS user commented that the system “is pretty cool”. This indicates
that the system has the potential of attracting users who are unfamiliar with traditional
operations to join the workforce by gamifying the operating process. This is another benefit
that is worthy of further study.

6. Conclusions
This paper has described a framework for integrating AR and DT to improve HCI
with smart devices by allowing remote monitoring and control, extracting knowledge from
data, and presenting in AR. The prototype ARDTMS shows a preliminary case study on a
tower crane. Through the user study, all three hypotheses were verified. Additionally, it is
encouraging to observe the significant statistical separation between the mean response
time for users of both systems. The qualitative result shows a preference for novice users
in selecting ARDTMS as the monitoring system. The study highlights some capabilities
which can be translated into HCI with other smart devices:
1. Utilize real-time data and historical data to provide assistive knowledge to improve
performance of novice users;
2. Visualizing real-time results in AR format, which is intuitive and easy to understand;
3. Implementable with commercially available hardware (mobile phones) and software
(Unity3D, Microsoft Azure, ARKit) to ensure the system can be built for every user
cost-effectively.
In the case study, the machine learning model showcases one possible way of using
DT data. The framework is compatible with more advanced algorithms. As an example,
if structural analysis is available for the DT, a finite element model can be integrated. As
a conceptual example, ARFEA presented a real-time simulation method based on the
quasi–static approximation to update the FEA result only on the region where the load is
added based on the data from the force sensor [41]. To integrate into ARDTMS, the same
computation algorithm can be preserved and transferred from a local computer to a cloud
server. Only the rendered result is needed to be transferred to the mobile device, and the
interaction scheme should be redesigned to fit the point-and-click interaction of a smart
phone.
The scope of the case study is limited by the availability of data. In this work, only
one device is studied, while multi-device interaction will have more complex effects in an
actual application. Further development can be performed by incorporating data from
a production shop floor. Nevertheless, the approach of utilizing real-time and historical
data to simulate and visualize device data using AR and DT is applicable for various smart
devices.
Data security is another issue overlooked in this study. Currently the data transmitted
is not encrypted. Additionally, as the XML data and JSON database are shared by multiple
users, there is a higher risk of losing proprietary information if any of the personal device is
lost or stolen. This can endanger the safety of operation and business performance if falling
into wrong hands. It is suggested that an in-house or outsourced information security
officer be involved when implementing the system for any business entity.
Ultimately, the framework of ARDTMS allows customized utilization and visualiza-
tion of DT data to improve a user’s decision-making process and take further actions. The
user or the service professional can investigate and decide what insight is important and
which analytics technique to integrate based on the application. In this way, ARDTMS
opens new opportunities to harness the power of DT data and AR interface to enhance
HCI for users to work smarter, more efficiently, and more effectively.

Author Contributions: Conceptualization, F.H., S.K.O. and A.Y.C.N.; methodology, F.H.; software,
F.H.; writing—original draft preparation, F.H.; writing—review and editing, F.H., S.K.O. and A.Y.C.N.;
Computers 2021, 10, 99 19 of 20

supervision, S.K.O. and A.Y.C.N. All authors have read and agreed to the published version of the
manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Data is contained within the article.
Conflicts of Interest: The authors declare no conflict of interest.

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