Digital twin-driven product design, manufacturing and service with big data
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.
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TL;DR: In this article , the authors propose to use the term digital twin system instead of digital twin because this highlights its complex interconnected substructure and addresses ethical concerns that result from treatment suggestions for patients based on simulated data and a possible lack of explainability of the underling models.
Abstract: The idea of a digital twin has recently gained widespread attention. While, so far, it has been used predominantly for problems in engineering and manufacturing, it is believed that a digital twin also holds great promise for applications in medicine and health. However, a problem that severely hampers progress in these fields is the lack of a solid definition of the concept behind a digital twin that would be directly amenable for such big data-driven fields requiring a statistical data analysis. In this paper, we address this problem. We will see that the term ’digital twin’, as used in the literature, is like a Matryoshka doll. For this reason, we unstack the concept via a data-centric machine learning perspective, allowing us to define its main components. As a consequence, we suggest to use the term Digital Twin System instead of digital twin because this highlights its complex interconnected substructure. In addition, we address ethical concerns that result from treatment suggestions for patients based on simulated data and a possible lack of explainability of the underling models.
3 citations
19 Mar 2020
TL;DR: In this paper, the authors investigated the use of smart technologies especially during the product design phase where the supply chain configuration will be conducted, and an UML model for smart product and supply chain design is proposed.
Abstract: The emergence of advanced smart technologies (e.g. Internet-of Things, Big Data Analytics, and Artificial Intelligence techniques) has created a number of innovations in handling supply chain activities and thus accelerate the transformation of the traditional supply chain towards a smart supply chain. Many existing studies focused only on applying smart technologies to facilitate smart manufacturing, but few ones addressed investigations covering smart technologies in the whole product lifecycle, namely the design and recovery stages. This paper interest focus on how smart technologies combined to product lifecycle management (PLM) contributes to realize sharing and integration of data in different lifecycle stages of the product? And how this could help to conduct a smart product and supply chain design? Moreover, the paper investigates the use of smart technologies especially during the product design phase where the supply chain configuration will be conducted. For this purpose, a framework is addressed and an UML model for smart product and supply chain design is proposed.
3 citations
TL;DR: In this article , a semi-automated data acquisition workflow was proposed for building energy modeling and simulation based on a methodology including hybrid simulation, building information modeling (BIM), and visual programming.
Abstract: Energy and resource efficiency as well as reduction of emissions are nowadays significant objectives for production companies. Industry 4.0, through extensive digitalization along the value chain, enables the achievement of these objectives not only in the construction of new facilities but also in existing facilities as well. This requires an interdisciplinary approach, extending over production and logistic processes as well as the building, technical building services, and energy supply systems, consolidated through integrated modeling and simulation-based optimization. The research question this study addresses is how to digitally couple these subsystems and optimize the overall system’s performance in terms of energy and resource efficiency, by distancing from silo-field thinking while using an integrated analysis approach. The article briefly presents a holistic modeling and simulation framework, utilizing modular digital twins (DTs) of all elements that may constitute a given industrial unit. The integration of multiple DTs of these subsystems in a hybrid (continuous and discrete) simulation forms a holistic DT ecosystem of an existing facility. The particular focus of the study is the building representation in this DT ecosystem for energy-efficient production. Based on a methodology including hybrid simulation, building information modeling (BIM), and visual programming, a semi-automated data acquisition workflow was proposed. The hybrid simulation is based on Discrete Event System Specification (DEVS) formalism, where the building is incorporated as a building energy model (BEM). Within the abstracted representation of the overall system, the article explores the possibilities of parametrizing the DT of the building, interconnected with the rest of the factory elements, by acquiring information directly from existing BIM models. Through a comparative case study, the proposed workflow is compared to a manual one in terms of integrity and benefits. The study’s contribution lies in: 1) the detection of the required building level of abstraction for a holistic DT ecosystem, 2) the definition of the interconnections between the building-related counterparts and the rest of the virtual environment as well as the data required for their parameterization, and 3) proposing a semi-automated workflow via virtual programming, for BIM-based creation of the building model within a holistic DT ecosystem.
3 citations
TL;DR: In this paper , the authors examine the connection between the digital twin and three related technologies (i.e., 3D printing, big data, and AI) and create a typology of four categories of digital twins (monitoring, making, enhancing, and replicating) and illustrate their relevance for innovation management.
3 citations
TL;DR: In this article , a perception-monitor-feedback system architecture is constructed based on the improved Gilbert-Johnson-Keerthi (GJK) distance algorithm, where the collision information of tool and machine can be better detected during simulation and monitoring of machine tool movement, and the more real workpiece shape can be displayed.
Abstract: The numerical control machine tool is an important part of manufacturing. The speed and accuracy of the machine tool simulation and the monitoring of machine physical model movement, model collision, and operation health are the most common bottlenecks. The previous studies on these problems are discrete and poor in real time. In this paper, combined with the digital twin (DT) technology, a perception-monitor-feedback system architecture is constructed. Based on the improved Gilbert–Johnson–Keerthi (GJK) distance algorithm, the collision information of tool and machine tool can be better detected during the simulation and monitoring of machine tool movement, and the more real workpiece shape can be displayed. Based on the model synchronous motion driven by the production perception data and its potential information extraction, the tool wear online monitoring is carried out. The tool wear online monitoring is performed based on the production perception data–driven model synchronous movement and extraction of its potential information. Finally, the usability and efficiency of the system are verified by an example of a typical shaft part processed by a numerical control machine tool.
3 citations
References
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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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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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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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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