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Journal ArticleDOI

Digital twin-driven product design, manufacturing and service with big data

Fei Tao1, Jiangfeng Cheng1, Qinglin Qi1, Meng Zhang1, He Zhang1, Fangyuan Sui1 
01 Feb 2018-The International Journal of Advanced Manufacturing Technology (Springer Science and Business Media LLC)-Vol. 94, Iss: 9, pp 3563-3576
TL;DR: In this paper, a new method for product design, manufacturing, and service driven by digital twin is proposed, and three cases are given to illustrate the future applications of digital twin in three phases of a product respectively.
Abstract: Nowadays, along with the application of new-generation information technologies in industry and manufacturing, the big data-driven manufacturing era is coming. However, although various big data in the entire product lifecycle, including product design, manufacturing, and service, can be obtained, it can be found that the current research on product lifecycle data mainly focuses on physical products rather than virtual models. Besides, due to the lack of convergence between product physical and virtual space, the data in product lifecycle is isolated, fragmented, and stagnant, which is useless for manufacturing enterprises. These problems lead to low level of efficiency, intelligence, sustainability in product design, manufacturing, and service phases. However, physical product data, virtual product data, and connected data that tie physical and virtual product are needed to support product design, manufacturing, and service. Therefore, how to generate and use converged cyber-physical data to better serve product lifecycle, so as to drive product design, manufacturing, and service to be more efficient, smart, and sustainable, is emphasized and investigated based on our previous study on big data in product lifecycle management. In this paper, a new method for product design, manufacturing, and service driven by digital twin is proposed. The detailed application methods and frameworks of digital twin-driven product design, manufacturing, and service are investigated. Furthermore, three cases are given to illustrate the future applications of digital twin in the three phases of a product respectively.
Citations
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Journal ArticleDOI
TL;DR: This paper thoroughly reviews the state-of-the-art of the DT research concerning the key components of DTs, the current development ofDTs, and the major DT applications in industry and outlines the current challenges and some possible directions for future work.
Abstract: Digital twin (DT) is one of the most promising enabling technologies for realizing smart manufacturing and Industry 4.0. DTs are characterized by the seamless integration between the cyber and physical spaces. The importance of DTs is increasingly recognized by both academia and industry. It has been almost 15 years since the concept of the DT was initially proposed. To date, many DT applications have been successfully implemented in different industries, including product design, production, prognostics and health management, and some other fields. However, at present, no paper has focused on the review of DT applications in industry. In an effort to understand the development and application of DTs in industry, this paper thoroughly reviews the state-of-the-art of the DT research concerning the key components of DTs, the current development of DTs, and the major DT applications in industry. This paper also outlines the current challenges and some possible directions for future work.

1,467 citations


Cites background from "Digital twin-driven product design,..."

  • ...They prescribed nine principles to improve the maintenance efficiency and reduce maintenance failure [51]....

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Journal ArticleDOI
TL;DR: It is shown, that literature concerning the highest development stage, the DT, is scarce, whilst there is more literature about DM and DS.

1,250 citations


Cites background from "Digital twin-driven product design,..."

  • ...(Tao et al. 2017; Lee et al. 2013a; Rosen et al. 2015) To get a more common understanding of the Digital Twin, the level of integration are discussed in the following section....

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  • ...(Tao et al. 2017) The Digital Twin in its origin describes mirroring a product, while the state of the art allows processes (manufacturing, power generation etc.) to be as well subjects of virtual space reproduction (“twinning”) in order to gain the very same benefits....

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  • ...…PPC MTConnect;MQTT;Database;NOSQL;Middleware Söderberg et al. (2017) concept DS PPC simulation Stark et al. (2017) review DS product lifecycle simulation Tao et al. (2017) concept DM PPC Semantic Web Terkaj, Urgo (2015) concept undefined PPC simulation, CPS Terkaj et al. (2015) concept DM process…...

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  • ...(Tao et al. 2017) It is the virtual and computerized counterpart of a physical system....

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Journal ArticleDOI
TL;DR: The findings show that Industry 4.0 is related to a systemic adoption of the front-end technologies, in which Smart Manufacturing plays a central role, and the implementation of the base technologies is challenging companies, since big data and analytics are still low implemented in the sample studied.

1,245 citations

Journal ArticleDOI
TL;DR: In this article, the authors studied how the adoption of different Industry 4.0 technologies is associated with expected benefits for product, operations and side-effects aspects in the Brazilian industry.

1,024 citations

Journal ArticleDOI
TL;DR: The role of big data in supporting smart manufacturing is discussed, a historical perspective to data lifecycle in manufacturing is overviewed, and a conceptual framework proposed in the paper is proposed.

937 citations

References
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Journal ArticleDOI
TL;DR: This review paper summarizes the current state-of-the-art IoT in industries systematically and identifies research trends and challenges.
Abstract: Internet of Things (IoT) has provided a promising opportunity to build powerful industrial systems and applications by leveraging the growing ubiquity of radio-frequency identification (RFID), and wireless, mobile, and sensor devices. A wide range of industrial IoT applications have been developed and deployed in recent years. In an effort to understand the development of IoT in industries, this paper reviews the current research of IoT, key enabling technologies, major IoT applications in industries, and identifies research trends and challenges. A main contribution of this review paper is that it summarizes the current state-of-the-art IoT in industries systematically.

4,145 citations


"Digital twin-driven product design,..." refers background in this paper

  • ..., internet of things technology and devices are employed to collect various data generated in the entire produce lifecycle [2], cloud technology is used to realize the data management and processing [3], and artificial intelligence is used for data mining and realizing added-value [4], the big data-driven manufacturing era is coming....

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Proceedings ArticleDOI
16 Apr 2012
TL;DR: In this article, the Digital Twin system integrates ultra-high fidelity simulation with the vehicle s on-board integrated vehicle health management system, maintenance history and all available historical and fleet data to enable unprecedented levels of safety and reliability.
Abstract: Future generations of NASA and U.S. Air Force vehicles will require lighter mass while being subjected to higher loads and more extreme service conditions over longer time periods than the present generation. Current approaches for certification, fleet management and sustainment are largely based on statistical distributions of material properties, heuristic design philosophies, physical testing and assumed similitude between testing and operational conditions and will likely be unable to address these extreme requirements. To address the shortcomings of conventional approaches, a fundamental paradigm shift is needed. This paradigm shift, the Digital Twin, integrates ultra-high fidelity simulation with the vehicle s on-board integrated vehicle health management system, maintenance history and all available historical and fleet data to mirror the life of its flying twin and enable unprecedented levels of safety and reliability.

1,183 citations

01 Jan 1965

792 citations


"Digital twin-driven product design,..." refers methods in this paper

  • ...The concept of product lifecycle was proposed by Dean [12] in 1950 and was used in product marketing strategy research by Levitt [13]....

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Journal ArticleDOI
TL;DR: A conceptual model of how the Digital Twin can be used for predicting the life of aircraft structure and assuring its structural integrity is presented and the technical challenges to developing and deploying a Digital Twin are discussed.
Abstract: Reengineering of the aircraft structural life prediction process to fully exploit advances in very high performance digital computing is proposed. The proposed process utilizes an ultrahigh fidelity model of individual aircraft by tail number, a Digital Twin, to integrate computation of structural deflections and temperatures in response to flight conditions, with resulting local damage and material state evolution. A conceptual model of how the Digital Twin can be used for predicting the life of aircraft structure and assuring its structural integrity is presented. The technical challenges to developing and deploying a Digital Twin are discussed in detail.

681 citations


"Digital twin-driven product design,..." refers background or methods in this paper

  • ...Structural Sciences Center at US Air Force Research Laboratory employed digital twin to build a realistic highfidelity flight model and combine virtual model data with physical data to make a more accurate fatigue life prediction [24]....

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  • ...Digital twin can update data in real time, so that virtual models can undergo continuous improvement through comparing virtual space with physical space in parallel [24]....

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Book ChapterDOI
Stefan Boschert1, Roland Rosen1
01 Jan 2016
TL;DR: This chapter focuses on the simulation aspects of the Digital Twin, where simulation merges the physical and virtual world in all life cycle phases and enables the users to master the complexity of mechatronic systems.
Abstract: The vision of the Digital Twin itself refers to a comprehensive physical and functional description of a component, product or system, which includes more or less all information which could be useful in all—the current and subsequent—lifecycle phases. In this chapter we focus on the simulation aspects of the Digital Twin. Today, modelling and simulation is a standard process in system development, e.g. to support design tasks or to validate system properties. During operation and for service first simulation-based solutions are realized for optimized operations and failure prediction. In this sense, simulation merges the physical and virtual world in all life cycle phases. Current practice already enables the users (designer, SW/HW developers, test engineers, operators, maintenance personnel, etc) to master the complexity of mechatronic systems.

668 citations