May 2023 Volume 5

AUTOMATION

and plants. When advanced visualization, IoT, and analytics are applied to these assets, manufacturers can take a more strategic and holistic approach to asset management.” The digital twin is not only a tool to model a real-life system, but a strong design tool that precedes reality. DTC indicates that manufacturing “is becoming increasingly digital. Digital twins are being applied during the engineering, design, production, and operations phases of a product lifecycle to improve products, predict, and detect problems.” Significantly, digital twins have captured the interest of no less than the U.S. Department of Defense (DoD), which published its Digital Engineering Strategy in June 2018.This study suggested that one way to modernize defense systems and prioritize speed of delivery for future conflicts is “by incorporating the use of digital computing, analytical capabilities, and new technologies to conduct engineering in more integrated virtual environments to increase customer and vendor engagement, improve threat response timelines, foster infusion of technology, reduce cost of documentation, and impact sustainment affordability.” The report concludes: “Transforming to digital engineering will allow for risk taking in a digital environment and increased rapid fielding of prototypes. Sectors of private industry and engineering centers in the DoD have embraced this transition, implementing digital engineering activities to great benefit.”

Sinclair Community College in Dayton, Ohio houses the Sinclair National UAS (Unmanned Aerial Systems) Training and Certification Center. The Center offers many advanced capabilities including in support of training and education, applied research and development, commercialization and technology transfer, modeling and simulation, and data analytics. Dr. Andrew Shepherd serves as the Executive Director and Chief Scientist of UAS, providing extensive experience in the defense industry and academia focused on modeling and simulation, research, course development, accreditation, instruction, and mentorship. Given Shepherd’s deep understanding of digital twins, digital threads, and data analytics, we asked his opinion on whether digital twin techniques were here to stay or just a phase of passing interest. He responded unequivocally, “Digital twin concepts will be permanent. They already have a head start in industrial and other systems’ modelling, design, and management. We are edging toward a situation in which top-tier manufacturers and government may, when appropriate, require digital twin ‘certification’ before they purchase a system or issue a significant contract. This creates a ‘pulling’ effect on demand for digital twins. Similarly, digital twins can also help small- and medium-sized operations that supply Tier I customers improve efficiency and save money, creating a ‘push’ in demand.”

Images of a digital twin for a Parrot AnafiUSAUnmanned Aerial System (UAS) as viewed in aMicrosoft HoloLens.This is used for manufacturing or maintenance training in an Augmented Reality (AR) environment. Courtesy of the Sinclair College National UAS Training and Certification Center.

Major corporations are, of course, already engaged in the development of digital twin resources. A visit to IBM’s Digital Twin Exchange webpage revealed much information about digital twin applications. This resource was discontinued in late March but will re-emerge as the Maximo Application Suite Catalog later in 2023. In the meantime, IBM is still active as a digital twin hub. In another example, Siemens, among its portfolio of digital twin projects, offers an eBook onmodelling and digital twins as applied to electric vehicle manufacturing. Here’s part of what they have to say: “A comprehensive digital twin represents every aspect of a product's life in the virtual realm, from design to in-use performance, including the processes employed to manufacture the product. The comprehensive digital twin is used to simulate, predict, and optimize a product and its production system before investing in

physical prototypes and assets. It provides valuable foresight before production and insights that drive continuous manufacturing improvements.” Digital twins are great tools for use in many different applications, but they are not perfect in every instance. For example, some operations are too small or not of sufficient complexity to warrant the time and expense required to create a digital replica. Every situation is different with varying needs, payback requirements, and budgetary or technical capacity. At present, projects that benefit the most from digital twins are mechanically complex systems (aircraft, autos), physically large projects (civic structures such as large buildings or road systems), and power generating and transmitting equipment.

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