The Future of Digital Twins in Mechanical Engineering: An Interview with MPA Technology

What exactly can be understood by a digital twin?

The digital twin (DT) is a model that replicates various service or manufacturing processes, product lifecycles, or functionalities of production machinery. Through gathered data, it establishes a connection between the real world and its respective virtual counterpart. Thus, it serves as a computerized model of a tangible or intangible object.

What types of digital twins are typically distinguished in mechanical engineering?

MPA Technology emphasizes different stages of development rather than distinct types of digital twins in mechanical engineering. Throughout a product's lifecycle (e.g., machine, cell, production line), digital twins are utilized for various tasks.

Initially, a basic DT model may be used for quoting purposes, often comprising a 3D model of the product with articulated assemblies to simulate and display operations. This model can be enhanced with virtual sensors during design to test cycle times, potential collisions, and evaluate process variants.

Vital to mechanical and plant engineering is the virtual commissioning, increasingly applied in recent years. Here, control (virtual or real) is integrated into the DT, enabling programmers to write and test programs before actual construction begins. Once the physical plant is operational, the digital twin can run in parallel, monitoring, visualizing, and analyzing data from the physical process. Integrated into Manufacturing Execution Systems (MES), the DT can control, evolve, and plan processes.

To what extent is the digital twin a relevant component of Industry 4.0?

In the context of Industry 4.0, characterized by individualized products and customer integration in production processes, MPA Technology asserts that the DT is a critical tool for centralized management. Its continuous evolution throughout the product lifecycle allows real-time analysis, simulation, improvement, and visualization.

What are some practical use cases of the digital twin in mechanical engineering?

Development: Virtual modeling of individual components (e.g., drives) enables behavior analysis and optimization with validated and verified models.

Planning: Analyzing data from similar processes aids in planning new process chains. Predicting and analyzing the effects of parameters on existing processes is facilitated.

Commissioning: Testing programmed control logic alongside construction helps ensure readiness before physical plant assembly.

Quality Management and Maintenance: Real-time monitoring allows early detection and mitigation of bottlenecks or failures.

Showroom: Simplifying the demonstration of various process flows, for example, at trade shows.

What should a mechanical engineer consider when developing a digital twin?

MPA Technology suggests first establishing appropriate infrastructure tailored to the specific application. Since the DT simulates processes in real-time, sufficient computational speed is crucial, especially as detail increases. For instance, when considering collisions, the model should include relevant physical properties only, adhering to the principle of simplicity.

Furthermore, stable and secure network communication is essential, as the DT integrates programs, interfaces, and services often operating on different systems. Given that sensitive process data is collected, attention to data privacy and security is paramount.

To fully leverage the DT's potential, MPA Technology advises involvement from project inception, considering subsequent phases to incrementally enhance model behavior. Clearly defining goals and benefits of the DT beforehand is recommended to avoid unnecessary effort.

Where do you see significant future potential for further development and deployment of the digital twin in mechanical engineering?

According to MPA Technology, the DT currently plays a crucial role in Industry 4.0, with anticipated increased relevance in Industry 5.0. Presently, focus in mechanical engineering lies in VIBN. Technologies like augmented reality and virtual reality integrated into the DT offer possibilities for virtual training and maintenance. Furthermore, advancements in artificial intelligence integrated into the DT enable virtual simulation and control of complex systems in diverse scenarios.

Looking ahead, MPA Technology is set to drive forward sustainable industrial practices with its cutting-edge Digital Twin solutions. Through the integration of AI and real-time data, MPA Technology enables businesses to optimize operations, enhance efficiency, and adapt swiftly to future challenges.