Step by step to the digital twin
The digital twin accompanies systems throughout their entire life cycle. According to conventional wisdom, the virtual counterpart only comes to life when a machine is actually commissioned. However, this does not mean that companies cannot benefit from the advantages of the digital twin much earlier in the development process. With the simulation model (also known as the digital prototype) as the basis of the digital twin, all development steps – from initial planning to assembly and commissioning – can be virtually validated. The digital prototype develops in parallel with the machine, can be varied, improved and tested and is finally available for virtual commissioning. Only when virtual commissioning has run smoothly does the company take the next step and start production at the operator’s premises.
Simulation models for virtual commissioning
In the classic process, in the days before virtual commissioning, manufacturers took the direct route via development, assembly, commissioning and production at the operator’s premises. And this often had fatal consequences: Without the opportunity to test the concepts virtually, it was only with the real commissioning that some planning errors, inconsistencies or necessary changes came to light. And it cost a lot of time and money to make changes to a finished machine.
With virtual commissioning, these risks can be minimized, if not eliminated, with the help of a digital prototype. In this case, virtual commissioning can be repeated as often as necessary until everything works perfectly. Only then is the machine built by the operator. The so-called transfer of risk shifts further and further forward in the course of the process. And the associated risks become smaller and smaller compared to the classic process.
Safeguarding all development steps and later the actual machine are indispensable for companies today. This also means that the classic process is history. If companies want to remain competitive today and thus meet the demands placed on them in terms of quality and speed, there is no alternative but to break new ground and bring the digital twin on board.
But how is the digital twin created in the first place? We divide the life cycle of the digital twin into three phases:
- Design and manufacturing phase: this first, important phase is about testing, modifying and optimizing the concepts. The virtual models are based on real data from the machine to be developed. This allows the digital prototype to be created under almost real conditions – the ideal basis for holistic engineering (continuous commissioning).
- Operational phase: Once the real machine has been commissioned, the “real” digital twin is directly available. Fed with all relevant data during the development process, it can take over the measurements and monitoring during operation with the real commissioning. Improvements and modifications can be easily implemented.
- Expansion of the machine: The knowledge gained from the operation of the digital twin is incorporated into further development. The simulation model is available to the machine manufacturer so that all planned expansions can be safely run through in advance. The result: only minimal downtimes are required for conversions or upgrades. This saves time and money.
