Digital twins improve manufacturing in reality


Alberto Ferrari, senior director of Model-Based Digital, said that the combination of real-world data and the digital simulation of the product (digital twin) provides valuable insights to help the company identify and solve problems before the prototype is put into production and the product is managed on site. Raytheon’s threading process Competence center.

“As they say,’All models are wrong, but some of them are useful,'” Ferrari said. “Digital twins that use data as real facts are a way of identifying models that are truly useful for decision-making.”

With the growth of the market for digital twin technology and tools, this concept has become popular 58% per year It will reach USD 48 billion by 2026, up from USD 3.1 billion in 2020. Using this technology to create digital prototypes can save resources, money and time. However, the technology is also used to simulate more areas, from urban populations to energy systems to the deployment of new services.

Take the manufacturer as an example Raytheon And Swedish breweries Absolute Vodka, They are using the technology to design new products and simplify their manufacturing processes, from the supply chain to production, and finally to recycling and disposal. Singapore, London, and Several cities along the Gulf Coast of Texas A digital twin of their community has been created to address all aspects of urban management, including modeling traffic patterns on city streets, analyzing architectural trends, and predicting the impact of climate change. Companies such as Bridgestone and drone service provider Zipline are using the technology in conjunction with operational data to help launch new services.

The company has adopted digital twins as part of its digital transformation, which is a way to simulate performance, identify weaknesses, and operate services more efficiently. Any company’s digital plan should explore whether certain aspects of its products, operations, or environment can be simulated to gain insights.

Analog design and manufacturing

Today’s digital twin technology is based on computer-aided design (CAD) and computer engineering tools developed more than thirty years ago. These software systems allow engineers to create virtual simulations to test product design changes. The engineer designs a product component on the computer, such as a wing, and then commissions a modeler or engraver to make objects from clay, wood, or stock components for physical testing.

Today, the process has shifted the prototyping phase to the latter part of the process, because the massive increase in computing power and storage not only allows the prototyping of the entire product, but also allows the integration of other information, such as information about the original product supply. Materials, components required for manufacturing, and operations of products on site.

Scott Buchholz, Deloitte Government and Public Service Chief Technology Officer and Emerging Technology Research Director, said: “If you look at those CAD and engineering tools 30 years ago, and then squint, you will find that these things are digital twins.” Consulting. “As computing power and storage capacity increase, so does the ability to perform useful simulations. We shift from low-fidelity rendering to high-fidelity simulation.”

The result is that digital twin technology has swept all industries. Manufacturers of expensive vehicles and infrastructure products benefit from shortened design and development cycles, enabling aerospace companies, automakers, and urban planning agencies to become early adopters. However, startups are also adopting a simulation-first mentality to quickly iterate product improvements.

One major benefit is that the digital twin pushes the physical construction of the prototype deeper into the design process. Nand Kochhar, vice president of the automotive and transportation industry at Siemens Digital Industries Software, said that some companies pursuing zero-prototype programs aim to completely eliminate the prototyping step and achieve direct-to-manufacturing efforts.

This is a huge change in the past. “The typical product development life cycle is 6 to 8 years,” Kochhar said of car manufacturing. “This industry has been working hard, and now they have a life cycle of 18 months or 24 months. Now, automobile manufacturing is more dependent on software, and software is becoming the decisive factor of the life cycle.”

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