Digital Twin Driven Smart Manufacturing

What is Digital Twin?

• Digital twin is a digital duplicate of a physical system designed to simulate, predict, prevent, and optimize physical manufacturing system through real-time process data and analytics.
• Applications of digital twins in the manufacturing life cycle management include product design and virtual prototyping, production, operation, and predictive maintenance.

• Machine condition monitoring and fault diagnosis (about 50% of all operating costs in most processing and manufacturing operations can be attributed to maintenance).
• Accurate and efficient simulation of manufacturing processes in the interest of prediction and prevention.
• Optimal sensor number and placement for optimal operation and process control and/or structural damage assessment.

Digital Twin based Fault Detection and Condition Monitoring of Rotating Machinery

• Rotating machine analyses are based on engineering models leading to Digital Twin model.
• Model validation and model-based identification are combined to detect and characterize the damage.
• Model validation is employed to detect a change in dynamics from the nominal, healthy system.
• Method is demonstrated experimentally on a minute source of structural damage caused by a circumferential cut in the rotor (1.8 mm deep, 0.6 wide).