Digital Twin Technology, Will Improve Future Products and Services ?.

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Digital Twin Technology, Will Improve Future Products and Services ?.

Digital twin technology are the innovation backbone of the future.

Digital Twin definitions (Mere namkaran.. You all are invited..) – Some people called me your are a replica of the physical asset ..Ok fine but I think I have some more ? .. Yes… a product in the form of digital not just looks but also in terms of the functionalities in terms of features.. Now, I am happy Let’s see what other say about me..

Digital twin definitions by Mr. A

– Digital twin integrate artificial intelligence machine learning and software analytics with data to create living digital simulation models that update and change as their physical counterparts change .

Digital twin definitions by Mr. B

– A digital representation of a unique occurrence of a physical product , used to gain greater insight into that product’s state, performance and behavior.

Digital twin definitions by Mr. C

– The Innovation Backbone of the future, delivering virtual representation of real-world products, systems and cities.

So , you can call me by any one of these Mr. A, B and C Definition …I don’t have any problem..

History – So how it started ?.

Meet my father or promoter .. Dr. Michal Grieves .. Please Say hey to him..

This term digital twin was originally coined by Dr. Michal Grieves in 2002. Dr. Michal Greaves chief scientist for advanced manufacturing at Florida institute of technology introduced the concept of digital twin at an American society of mechanical engineer conference in 2002. 

Let me introduce my first home .. NASA.. Apollo 13 (My first birth Apollo 13)

In 1960s NASAwas one of the first  agencies to uses mirroring technology to replicate systems in space for space exploration missions , NASA created a replica of Apollo 13 which become critical in the midst of its challenging mission , engineer were able to test solution on the replica to avoid further disaster.  

Why I came into the picture ?… To improve future products and services … oh yes i am so useful na right ?.

What is the real purpose of digital twinFeedback loop..(Product life management –Feedback is missing)

We are have been making product from several years now. We start with conceptualize product , you innovate product ,you try R& D part of it , we manufacture it and than we just sell it ,give it to someone to start using it. who knows how an where it has been use, whether it has been use or missed use , whether could be potential improvements which can be done if so, where is the feedback loop to the rest of the organization including the concept people the R&D people, manufacturing people what can be improved in product ?.

From digital twin ,we are trying to achieve here is used the real-time data coming from the field services and coming from real use cases without going on the field and bring it back to the Enterprise to use that knowledge in the information to improve future products and services and the trying to do that using the concept of digital twin where we have a replica of the physical asset and a product in the form of digital not just looks but also in terms of the functionalities in terms of features in for and the behavior to feedback real-time data to the digital model so that we can simulate practically everything which can happen in the field.

..Little difficult to understand example please …Ok.. In development , a product’s behavior can be simulated and tested long before a physical prototype has been built. .

For example , In case of wind turbine, can be used in different circumstances in different areas , it can be used in offshore on side it can be used in very cold conditions, it can go to all kind of mess in terms of weather temperature, humidity and so on ..

There is a challenge for the wind turbine producer and power company to predict how much of power will be produced in next 1 week or one month because we all need a certain predictable power available at our home and the OEM needs how the wind turbine is functioning in a certain place

So to be able to close that loop,  people are trying to bring the data back and People are trying to make a simple use case where the availability of wind turbine be calculated with 360 degree view of the data in terms of how much failure happened last 5 years, how much of inventory has been use of certain part, how is the weather condition changed over the last 20 years can I predict the weather pattern , So that we have a very solid model with which can do Artificial Intelligence and machine learning to be able to predict much better failure predict, much better power output and also available turbine. 

How it works ?.

Digital twins connect the real and virtual world by collecting real time data from the installed sensors.

The collected data either locally decentralized or centrally stored in a cloud . The data is then evaluated and simulated in virtual copy of the assets, After receiving the information from the simulation the parameter applied to real assets, This integration of data in real and virtual representations help in optimizing the performance of real assets.

The market for the technology is set to hit $15.66 billion by 2023. by 2022 half of large industrial companies will be using digital twins to transform the way they approach manufacturing and customer service.

BySiemens… Startup coming …

Siemensutilized the digital twin to develop a world record –setting , electric aircraft motor that not only weight 50 Kilograms, but is also five times more powerful than comparable electric motors but doesn’t stop there. Digital twin also unless the power of 3D printing. In recent Siemens study for gas mixing system. Insights from the simulation of form and flow behavior were combined with generating algorithms. The Results ? .

A truly unique channel shape and configuration one significantly more efficient then any thing previously designed even entire factories down to individual machines can be simulated and tested. for instant robot it’s difficult for them to perform milling tasks because large forces in manufacturing process lead to inaccurate moments but with the digital twin the forces that push the robot away from milling path can be calculated and compensated in the real time keeping robot in its path .

When itcome to operation, digital twin can compare the sensor data of a real point in real time with the simulation of its on point. The availability of the point parallel to operation can be reliably predicted and sudden disruptions becomes a thing of the past. Siemens merging digital twins with artificial intelligence allows computer to independently design advanced products.

Siemensis realizing this potential right now withCalifornian Startup Hackrod, which aim to build customized sport cars.For development, production and operation , the digital twin breaks with traditional paradigms and opens up extraordinary Possibilities.That’s way digital twin are the innovation backbone of the future.

Its Applications :

Digital twin can we used in various industries.






Digital twins optimize the manufacturing process and expects to save millions of dollars in maintenance costs

Digital twinsusetooptimize the machineswith the maintenance of power generation, equipment such as power generationturbine jet engines and locomotive.

Digital twin: will increasingly be use in many area such building management, smart building , healthcare, oil and gas smart cities and far more.

Engineer get information of the product usages in the real world can include the information they gather forfurther development.

The digital twingive easy access to advanced product assetsmaintenance and management due to it real time nature decision making is easier in highly complex cases for example.

Digital twin helps inoptimizing processes, reducephysical efforts and help control all aspects virtually with the help of this technology consumer insights and behavior data gathered can help improve product development and innovation in more data and customer driven.

Digital twin are the next big thing in Fourth Industrial Revolution for the development of new products and process.

Simulation-based digital twins product in markets – ANSYS TwinBuilder and PTC Thingworx

ANSYS TwinBuilder -: Build, Validate and Deploy Simulation-Based Digital Twins.

ANSYS Twin Builder improves predictive maintenance outcomes to save on warranty and insurance costs and optimize your product’s operations. To build your system easily and quickly, Twin Builder combines the power of a multidomain systems modeler with extensive 0D application-specific libraries, 3D physics solvers and reduced-order model (ROM) capabilities. When combined with embedded software development tools, Twin Builder allow you to reuse existing components and quickly create a systems model of your product. To validate your system and ensure expected performance, Twin Builder combines multidomain systems simulation capabilities with rapid human-machine interface (HMI) prototyping, systems optimization and XiL validation tools.

To connect your twin to test or real-time data, Twin Builder easily integrates with industrial internet of things (IIoT) platforms and contains runtime deployment options, allowing you to perform predictive maintenance on your physical product. It is the only product that offers a packaged approach for your digital twin strategy

PTC Thingworx  – : PTC’s Thingworx IoT platform provides the means through which the sensor data is collected and communicated. Representations of virtually every aspect of our world will be connected dynamically with their real world counter part and with one another and infused with AI based capabilities to enable advanced simulation operation and analysis.

How digital twin will going to help conventional simulation (Finite Element Analysis /CAE) Why Bother?.

Conventional simulation (based on FEA) does not scale well to large and/or complex models which have many “FEA degrees of freedom.” As a result, engineers have developed work-arounds for large-scale models based on coarse modeling or submodeling, which inherently sacrifice accuracy.

Physics-based simulation models (CAE) have proven their mainstream business value during the development and manufacturing phases of the Product Performance Life-cycle (PPL).

Now they are moving beyond those phases into the entire life cycle of products and systems by being updated/modified to reflect the ongoing true in-field status/condition of such products and by being subject to the actual in-field loadings and boundary conditions obtained from sensors (the Industrial Internet of Things – IIoT). The resulting Digital Twins can then be used to anticipate needed maintenance and predict the behavior of future proposed operational changes to the physical structures and systems they represent in digital form.

Key enablers are the increasing accuracy of CAE models, the declining costs of high-performance computing, expanding cloud accessibility, and low-cost sensors.

As per company called Akselos : Akselos is the creator of the world’s most advanced engineering simulation technology – physics-based, real-time digital twins. Founded in 2012 and with operations in Europe, the USA, and South East Asia .

Akselos’ advanced reduced basis modeling technology, enable holistic and detailed modeling of large scale and/or highly complex systems, so that engineers no longer need to sacrifice accuracy in order to perform their analysis. Holistic and high fidelity modeling is also the foundation of Akselos’ Digital Twin platform – a single model that incorporates the current (as is) and future (as could be) conditions of the asset. Full scale system modeling also allows to remove unwanted conservatism from analysis workflow.



Reduced Basis Finite Element Analysis (RB-FEA) enables 100x larger-scale and 100x to 10,000x faster analysis than FEA for large models. This makes it possible to create a fully detailed 3D virtual model of your complete structure (regardless of the size), without sacrificing accuracy.


Add, remove, replace components to efficiently modify and re-analyze large and small models. Change parameters in components to incorporate new data, or “what if” scenarios.


Our models live on the cloud. They are accessible from anywhere in the world, and at any time, enabling your organisation to collaborate more effectively. Scalable cloud computing also supports the rapid mapping of a design space or produces rich, physics based data sets to augment the predictive capabilities of conventional digital twins


Automated report generation based on industry standards that provide decision support for operational decision-making, e.g. fitness-for-service of critical assets, risk-based inspection planning, asset fatigue accumulation based on up-to-date sensor measurements, etc.


Solve large-scale nonlinear problems via Akselos’ Hybrid Solver, which couples FEA and RB-FEA in one analysis. This provides a “best of both worlds” approach to nonlinear analysis: the accuracy and flexibility of FEA for nonlinear analysis, and RB-FEA acceleration to regions of the model in which there is no nonlinear behavior.

Company looking for cases where cut the physical can using digital twins 

Thank you so much. I hope the above information helps you in understanding digital twin.

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