As the name suggests, a digital twin is a virtual replica of a particular object or system. Fitted with sensors, the real-life asset sends data to the digital twin for more informed decisions based on simulation and machine learning. For instance, you might have a digital twin of a factory machine, with tests run in the virtual environment to assess its performance in various scenarios. This can help in the identification of potential problems and adjustments for optimum performance. Read on as we explore such digital twin applications and benefits here.
The Lifecycle of Production: Digital Twins in Action
Various types of digital twins can be applied for assessment during each stage of the production lifecycle. At their most basic level, digital twins can be used to establish the effectiveness of individual parts and components. Then there are system or unit twins, which can be used to assess the combined effectiveness of assets within a complete functioning system. Process twins can also be used to see how well systems work together within a complete production facility.
Design and Engineering
The ability to assess the functioning of parts within the virtual environment minimises the need for the time-consuming and expensive use of physical prototypes. Manufacturers may use digital twins to gauge how well systems work under specific conditions and identify any flaws or faults that will have to be dealt with for optimal performance. Various adjustments can be made in the virtual environment before committing to production.
Simulation at Different Levels
As mentioned, digital twins may be used to assess the performance of a single machine, a more extensive production line, or a complete factory. They can highlight the need for predictive maintenance and the potential to enhance production with different layouts and workflows.
Virtual Commissioning
Using a digital twin, it’s possible to see how well an individual component or complete system will perform before approval. Engineers can run tests and make adjustments to prevent issues that might otherwise occur during assembly and installation. This should minimise downtime and accelerate project timelines.
Digital Twins: The Foundation for Confident Decision-Making
It has long been common to review past data for increased decision-making confidence. Digital twins take the power of analysis to the next level, enabling manufacturers to see the impact of various changes on performance in real-time. Powered by machine-learning models, digital twins can be used to establish the kinds of issues likely to arise following the implementation of new systems and processes. Decision-making can be improved through the simulation of different scenarios, as with the raising of machine performance demands.
The scope for this kind of evaluation increases with the development of sensors and analytical technologies. With more real-world data, the digital twin can more accurately model the impact of changes and provide more valuable insights.
Focusing on the manufacturing environment, digital twins can be used to:
- Accurately predict machine failures and the need for preventative maintenance
- Identify the ideal workflows and machine settings for optimum performance
- Virtually refine new products and processes for faster time to market
- Improve efficiency and quality consistency
Digital Twins in Action
With trends such as the fourth industrial revolution gathering pace, more manufacturers are turning to digital twins for optimisation of the product lifecycle. This is leading to the wider realisation of benefits such as rapid time-to-market and improved productivity. A Forrester Consulting Study has revealed that 80% of companies implementing such immersive technologies have seen improvements in innovation and collaboration across the production, manufacturing, and operations work phases.
ABB Robotics has realised such benefits through the integration of its PickMaster® Twin software with digital twin technology. This has enabled the trialling of different robotic configurations on virtual production lines before real-world commissioning. Digital twin adoption has improved flexibility and visualisation in the assessment of robotic applications, with commissioning times being reduced from days to hours and changeover periods from hours to minutes.
Able to create, simulate, and test a complete robot installation in the virtual environment, customers can avoid the disturbance of real-world production lines. This also reduces the time to market for new products, with the rapid installation of new product lines and the limitation of commissioning risks. It's a key benefit for today’s manufacturers, given the expectations of mass customisation and reduced product life cycles.
Successful Implementation
There are a number of best practices that should be followed when it comes to the implementation of digital twins. Firstly, there’s the matter of selecting the correct model according to your intended application and objectives. Digital twins could be adopted within the manufacturing space for such purposes as optimising machine layouts, training robots, or providing operators with immersive and cost-effective training. There may also be specific goals in terms of improving operational efficiency, minimising maintenance costs, and enhancing product quality.
The accuracy of the digital twin will depend on the accessibility of data through sensors, IOT devices, and other sources. There must also be systems in place to ensure the security and effectiveness of such data. The digital twins may be trialled and assessed to see how well they work within the manufacturing environment. Feedback should also be gathered and any technological or compatibility issues dealt with before full reliance on the technology. As the benefits are realised and confidence is gained, digital twins can be introduced for the more comprehensive assessment of manufacturing assets, processes, and units.
Of course, there are challenges to be overcome, with manufacturers potentially being perturbed by the investment of time and money needed for successful implementation. However, this will become less of an issue given ongoing digital twin development and support. Knowledge sharing will also be of benefit, with manufacturers learning how to combine and safeguard vital data. There must be a commitment to change and the adaptation of workflows for the most effective use of digital twin insights.
Embracing the Advantage
From the optimisation of factory space to the enhancement of product quality and innovation, there are numerous benefits to be realised with digital twins. Such benefits will be showcased by various manufacturing businesses exhibiting at the upcoming PPMA Total Show. Being held at Birmingham’s NEC from the 23rd to the 25th of September, this will provide the opportunity to expand your network and gain insights into such immersive technologies. Go ahead and register for your ticket today.