Digital Twins

What is a digital twin?

A digital twin is a virtual representation of a physical object or process. It is primarily used when companies want to observe, analyze, simulate, and optimize their products or systems over their entire lifecycle. To do this, models, information, and data are continuously collected from the real object or process in real time, providing insight into its condition and behavior.

How does a digital twin work?

A digital twin has three basic components: A digital master, a digital shadow, and their intelligent linking. 

 

1. Digital master

The digital master contains all relevant models of the physical object or process. It uses appropriate data and information models to represent what is expected. Depending on the application, this may relate to the geometry, behavior, function, or other properties of products, machines, or processes.

Digital Twins are created by linking the digital shadow and digital master.

A car is used as an example. All cars of a type have been produced using the same drawings and production instructions, and have the same average maintenance cycles. We call the models, simulations, and data from which all these cars are produced »master«.

 

2. Digital shadow

The digital shadow, on the other hand, represents the actual. It consists of data that is collected over the life cycle of the system depicted. This can be operating, status or process data that is recorded by sensors, for example.

The data shows the differences between each car, even though they are identical in construction. This is due to the fact that each car has been subjected to special features during production, such as assembly variations. During operation, the car may have been used in particularly hot, cold or dry regions, requiring shorter maintenance cycles. We call this data, which represents the reality of the unique car, »shadows«.

 

3.  Intelligent linking

The real value of the digital twin comes from intelligently linking the digital master and the digital shadow.

By comparing the vehicle's master and shadow data, it is possible, for example, to predict the optimum time for maintenance or to derive important improvement potential for future product generations (feedback to design).

What types of digital twins are there and what are they used for?

 

Product twins

Product twins are digital images of real, individual objects of value. They contain data throughout their lifecycle and provide insights into product behavior and optimization potential. For example, they can be used to share data across organizations, or to plan, monitor, and optimize products at all stages of their lifecycle, including their environmental footprint and energy efficiency.

 

Machine twins, system twins and technology twins

Machine or plant twins map the current status during production. This allows us to automatically record and control the energy efficiency of systems or identify maintenance requirements at an early stage (predictive maintenance) and support maintenance with the help of context-sensitive assistance systems.

 

Process twins

Digital process twins link technical factory processes with enterprise business processes. This allows us to look at systems as a whole and gain important insights, such as production planning or business models, from a solid data foundation.

Application example: Faster development thanks to digital twins

 

Our researchers have developed a pilot system on which linked production systems can be designed cost-effectively and complex processes safely tested. The principle: A digital twin of the modular development environment ensures that the two robots are automatically configured and controlled for each assembly step.

Advantages of the solution

using the example of the automation of an assembly process for professional tools

Time and cost savings of a robot-based system compared to a traditional pilot system:

  • Pilot system in only 12 weeks instead of 12 months
  • Cost of about 175,000 € instead of over 2 million €
© Fraunhofer IPK/Ilona Glodde

Is your organization ready for the digital twin?

 

The industry has recognized the promise of digital twins as a future technology. According to a Gartner study, only 13 percent of large companies with ongoing IoT projects in major industrialized nations are currently using digital twins. However, 62 percent of respondents have such projects at least in the planning stage.

But even in companies where digital twins are in place, they are far from being used to their full potential. So far, they are mostly used as data supply systems or for security and error analysis. This is the conclusion of the »Digital Twin Readiness Assessment« study conducted by Fraunhofer IPK and msg in 2020, which found that the provision of automated value-added services and the design of autonomous or adaptive systems have only been considered in a few concepts to date.  

To fully exploit the potential of digital twins, we develop customized solutions in close cooperation with our partners and customers. We network digital twins with each other and thus enable the mapping of entire production lines with minimal time and financial expenditure. In doing so, we always keep an eye on the sustainability aspect, as the technology also offers new possibilities in this area.

How can we support you?

Here we show some examples of problems from industrial applications that can be solved with the help of digital twins. 

 

Solution

Digital twins for the circular economy

  • Closing information and material loops to promote a circular economy.
  • Design products that take into account all stages of their life cycle.
  • Reduce waste and recycle products at the end of their useful life.
 

Solution

Sustainability with the help of digital twins

  • The responsibility of product developers to design products optimally across all lifecycle phases.
  • Think ahead of the life cycle phases as part of product life cycle management.
  • Collect and evaluate a wide range of information to determine the true sustainability of a product or system.
 

Solution

Development and operation of digital product and factory twins

  • Digital twins enable current state analysis, forecasting, real-time optimization, and virtual rescheduling.
  • Support the development and operation of digital product or factory twins.
 

Solution

Models and modeling of digital twins

  • A variety of models for purpose-built digital twins: Use different types of models for development and simulation.
  • Methodological support: 8D model support for optimal design of digital twin solutions.
 

Solution

IT architectures and infrastructure for digital twins

Data consistency, heterogeneous system landscapes and cross-company collaboration place high demands on the robustness, flexibility and extensibility of the IT system architecture and the technologies used. With the Design Element Model, we offer conceptual support in the design and planning of your IT architectures and infrastructures and equip you for the use of digital twins.

Read more in the FUTUR magazine

 

FUTUR-Article

Design faster with digital twins

Our researchers have developed a pilot system on which linked production systems can be designed cost-effectively and complex processes safely tested. The principle: A digital twin of the modular development environment ensures that the two robots are automatically configured and controlled for each assembly step.

 

FUTUR-Article

All hands on deck

Today's complex products have a significant »digital component«. Key functions along their lifecycle have moved from the physical world into virtual data rooms. Entire production facilities are controlled by digital twins, and smart products record more and more data. New recycling requirements make the use of data inevitable.

 

FUTUR-Article

Digital (T)Wins

To control highly complex systems, companies are already using digital twins in many cases. Digital twins are digital replicas of a specific product, production system, or entire factory, allowing their characteristics, status, and behavior to be captured, predicted, and controlled using models, information, and data.

 

FUTUR-Article

A GPS for production

»Turn right in 500 meters.« When driving, we like to rely on digital assistance in the form of a navigation system. Wouldn't it be nice if such simple instructions could also be given in complex production processes? Fraunhofer IPK develops solutions for digital assistance systems  that provide users with individual and customizable support.

 

FUTUR-Article

Context is everything

In the area of maintenance, repair and overhaul (MRO), mobile assistance applications are in vogue because it is especially important to document the steps taken to maintain machines and systems so that other workers can understand what work has been done. AI makes this more flexible - and more predictive. 

Publications about Digital Twins