digital twins in manufacturing - a global institute

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Digital Twins in ManufacturingTechnical Topic Webinar

Dr. Milind SiddhpuraCourse Coordinator and LecturerMechanical & Civil Engineering

Presented by

Thursday 13th May

Download Webinar Recording Here

https://vimeo.com/549102561/0657b3847a


1 Introductions

2 What is a Digital Twin?

3 How does it work?

4 3 levels of Digital Twins

5 Benefits of Digital Twins

6 Digital Twin Applications

7 Tools for Digital Twins

8 Some Challenges

9 The Road Ahead

10 Q&A

Agenda


➢ Over 18 years of experience as an academic in top Australian and overseas universities.

➢ PhD in Mechanical Engineering from UWA.

➢ Received prestigious awards from the Australian government and published in high-ranking international journals and conferences.

➢ Course Coordinator in Mechanical and Civil Engineering at EIT.

➢ Responsible for developing and maintaining highest quality in the Bachelor’s, Master’s and Doctorate of Engineering courses.

➢ Why I joined EIT?

- Full focus on ‘Engineering’

- Industry relevant: Internships > Jobs

- Global industry experts teaching engineering

Dr. Milind Siddhpura


“A digital twin is a virtual representation of an object or system that spans its lifecycle, is updated from real-time data, and uses simulation, machine learning and reasoning to help decision-making.”

What is a Digital Twin?

https://www.ibm.com/blogs/internet-of-things/iot-cheat-sheet-digital-twin/


• A few Definitions of Digital Twin [2]:

What is a Digital Twin? Definitions


• Forefront of Industry 4.0

• Effortless integration of data between physical and virtual machine in either direction

• Facilitated through – Advanced Data Analytics

– Internet of things (IoT)


[4] B. Schleich, N. Anwer, L. Mathieu, and S. Wartzack, “Shaping the digital twin for design and

production engineering,” CIRP Annals, vol. 66, no. 1, pp. 141–144, 2017, doi:

https://doi.org/10.1016/j.cirp.2017.04.040.



Evolution of digitalization paradigm [1]


What is a Digital Twin? - History

The Milestones of DT development [1]


Digital Twin: Manufacturing meets its match


Digital Twin: A Sum of Constituent Parts

https://cdn.osisoft.com/osi/webinars/19.09.11-Thought-Leadership-Digital-Twin.pdf


• Key driving technologies:

– Virtual Reality

– Augmented Reality and Mixed Reality

– Internet of things

– Big Data

– Cloud Computing

– Machine Learning

• Digital Twin connects real and virtual worlds by collecting real time sensor data using IoT connected sensors.

• In this real time asset data is stored in the cloud.

• Where this data is analyzed and simulated in virtual copy of assets / products.

• These simulation studies and data is used to optimize a product performance.

How does it work?


Sensors

A digital platform

Communications networks

How does it work? 3 main elements


How does it work?: Manufacturing process example

Source: Deloitte University Press


Activity

Categorise the equipment/technology into appropriate domain:

Physical Digital

Pumps and CompressorsTemperature Sensors

Temperature DataActuators

Communication networkAutoCAD models

AnalyticsAir receiver/tank

AI/Machine LearningCloud Computing

CNC Machines


Example: How does it work?

How does Digital Twin Technology work – an example [4]


3 levels of the Digital Twin:

Digital model:- a digital version of a pre-existing or

planned physical object- no automatic data exchange

between the physical model anddigital model.

- Examples: plans for buildings,product designs and development.

- The important defining feature:there is no form of automatic dataexchange between the physicalsystem and digital model.

Digital shadow:- A digital representation of an

object that has a one-way flowbetween the physical and digitalobject.

- A change in the state of thephysical object leads to achange in the digital object andnot vice versus.

Digital Twin:- If the data flows between an

existing physical object and adigital object, and they are fullyintegrated in both directions, thisconstituted the reference “DigitalTwin”.

- A change made to the physicalobject automatically leads to achange in the digital object andvice versa.

3 levels of the Digital Twin [2]


Understand the present and predict the future!

Digital twins help manufacturers and engineers accomplish a great deal, like:

• Visualizing products in use, by real users, in real-time

• Building a digital thread, connecting systems and promoting traceability

• Refining assumptions with predictive analytics

• Troubleshooting far away equipment

• Managing complexities and linkage within systems-of-systems

Benefits of Digital Twin:


Digital Twin Applications:

Different Application Fields of DT [1]


Application of Digital Twin in Industrial Manufacturing


Digital Twin Applications: Manufacturing

•What-If Simulations.

• Reduced Product Time to market.

• Root Cause Analysis

• Reduced Prototype Cost

• Improved Product Design. and Reliability

Continuous Engineering and

Design

•The engineers can commission and run the plant virtually without actually building it.

•This allows automation engineers to detect and solve the problems in the early design stage.

Production Line and Machines Virtual Commissioning

•A machine digital model along with machine learning algorithms is used to monitor and predict the problem in a machine before it actually occurs.

•This also helps in diagnosing the problem remotely.

Predictive Maintenance and Remote Diagnosis


Digital Twin Applications: Real World UsesPower tool maker Black& Decker, have extendedthe digital twin conceptto encompass digitallymodelling assembly linesand other factorysystems, helpingmanufacturers boostproductivity andefficiency.

Jet engine maker Rolls-Roycealready uses Engine HealthManagement (EHM) to track thehealth of thousands of engines,using onboard sensors and livesatellite feeds. These data areused to enhance maintenanceregimes. Eventually they couldbe used in the original aeroengine design process.

Chevron expects to save millionsof dollars in maintenance costsfrom the digital twin technologythey will have deployed onequipment by 2024 in oil fieldsand refineries.

Digital twin technology haseven been deployed to refineFormula 1 car racing. In asport where every secondcounts, a simulation can helpthe driver and the car teamknow what adjustments canimprove performance.

General Electric(GE) usesthe digital twin tomonitor and controlturbines on its windfarms. They resolve theproblem when itgenerates some updationabout turbines.

There is even a digital twin ofSingapore! Imagine all thevariables that go into themanagement of a city. Digitaltwin technology helps cityplanners understand andimprove the efficiency ofenergy consumption as wellas many applications that canimprove life for its citizens.


Adoption of Digital Twin in Industrial Manufacturing


Application of Digital Twin in Industrial Manufacturing


?

What industry would you try DT?


Tools for Digital Twins

Framework of enabling technologies for digital twin [1]



Framework of tools for digital twin [1]



Tools for cognizing and controlling physical world [1]

Tools for digital twin modelling [1]

Tools for digital twin data management [1] Tools for digital twin service applications [1]

Tools for connections in digital twin [1]


Data Analytic Challenges

• IT Infrastructure

• Data

• Privacy and Security

• Trust

• Expectations

IoT/ IIoT Challenges

• Data, privacy, security and Trust

• Infrastructure

• Connectivity

• Expectations

Digital Twin Challenges

• IT Infrastructure

• Useful Data

• Privacy and Security

• Trust

• Expectations

• Standardized Modelling

• Domain Modelling

Challenges


The future: Cognitive digital twin


Road Ahead

https://www.compositesworld.com/articles/digital-twin-digital-thread-and-composites


• Pursue Mechanical Engineering/Industrial Automation courses.

• Pursue Extra Elective subjects: Programming; big data analysis; Machine Learning; IoT; Cloud computing;

• Project based learning: Try to implement new knowledge (extra courses above) in your real life projects.

• Practice and develop VR, AR based projects

• Build truly multidisciplinary teams at work

• Connect with Industry Experts

• Read technical papers to learn about the state of the art

• Attend webinars like this!

• Break the geographical barriers – Go online!

Gearing up for Digital Twin & Industry 4.0


How EIT is gearing up for the future

Online Learning

Synchronous and Asynchronous

Global Lecturers:

Network of 300+ lecturers

with strong industry

experience.

Virtual and Remote Labs

High quality and realistic virtual and

remote labs with 24/7 access

Online Libraries

Journals and

memberships with

IEEE and ISA

Global Students:

Over 1400 in over

146 countries.


• [1] Q. Qi et al., “Enabling technologies and tools for digital twin,” Journal ofManufacturing Systems, 2019, doi:https://doi.org/10.1016/j.jmsy.2019.10.001.

• [2] A. Fuller, Z. Fan, C. Day, and C. Barlow, “Digital Twin: EnablingTechnologies, Challenges and Open Research,” IEEE Access, vol. 8, pp.108952–108971, 2020.

• [3] F. Tao, M. Zhang, and A. Y. C. Nee, Digital twin driven smartmanufacturing. Academic Press, 2019.

• [4] “What is Digital Twin Technology : Working and Applications,” SMLeaseDesign, Dec. 09, 2018. https://www.smlease.com/entries/technology/what-is-digital-twin-technology/ (accessed Sep. 07, 2020).

• [5] “Digital Twins for Industry 4.0: Applications, Benefits, and Considerations |BehrTech Blog,” BehrTech, Feb. 06, 2019. https://behrtech.com/blog/digital-twins-for-industry-4-0/ (accessed Sep. 07, 2020).

• https://www.ibm.com/blogs/internet-of-things/iot-cheat-sheet-digital-twin/

References:

https://doi.org/10.1016/j.jmsy.2019.10.001


✓ 1 Introductions

✓ 2 What is a Digital Twin?

✓ 3 How does it work?

✓ 4 3 levels of Digital Twins

✓ 5 Benefits of Digital Twins

✓ 6 Digital Twin Applications

✓ 7 Tools for Digital Twins

✓ 8 Some Challenges

✓ 9 The Road Ahead

✓ 10 Q&A

Summary


Upcoming EIT Technical Topic Webinars

• Power System Stability in Microgridshttps://www.eit.edu.au/event/power-system-stability-in-microgrids/Join Dr. Imtiaz Madni, an Electrical System Engineer working within the Energy industry, to learn more about Power System Stability in Microgrids. Date: 3rd of June 2021Time: 4:30 pm - 5:30 pm

• What if Leonardo da Vinci used CAD Software?https://www.eit.edu.au/event/what-if-leonardo-da-vinci-used-cad-software/Join Dr. Arti Siddhpura, one of EIT’s Mechanical Engineering Lecturers, to find out what would have happened if Leonardo da Vinci used CAD Software. Date: 17th of June 2021Time: 3:00 pm - 4:00 pm

https://www.eit.edu.au/event/power-system-stability-in-microgrids/

https://www.eit.edu.au/event/what-if-leonardo-da-vinci-used-cad-software/


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Q & A


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digital twins in manufacturing - a global institute

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