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Alberto Ferrari, Senior Director of Model-Based Digital, says real-world data paired with digital simulations of products (digital twins) provide valuable information that helps companies identify and solve problems before prototypes go into production and manage products in the field. Thread Processing Capability Center at Raytheon.
“As they say, ‘All models are wrong, but some are useful,'” says Ferrari. “Digital twins, backed by data as real facts, are a way to identify patterns that are really useful for decision making.”
The concept began to rise with the growth of the digital twin technology and tools market. 58% per annum From $3.1 billion in 2020 to $48 billion in 2026. Using technology to create digital prototypes saves resources, money and time. Yet technology is used to simulate much more, from urban populations to energy systems and the delivery of new services.
Get manufacturers as diverse as possible Raytheon and the Swedish distillery absolute vodkaCompanies that use technology to design new products and streamline production processes, from supply chain to manufacturing and ultimately recycling and disposal. Singapore, London, and several Texas Gulf Coast cities They created digital twins of their communities to tackle various aspects of city management, including modeling traffic patterns on city streets, analyzing building trends, and predicting the impact of climate change. Companies like Bridgestone and drone service provider Zipline are using technology paired with operational data to help launch new services.
Companies have adopted digital twins as part of their digital transformation as a way to simulate performance, identify weaknesses, and run services more efficiently. Any company’s digital venture should explore whether some aspect of its product, operations or environment can be simulated to gain insights.
Simulation design and production
The foundations of today’s digital-twin technologies are found in computer-aided design (CAD) and computer engineering tools developed over three decades ago. These software systems allowed engineers to create virtual simulations to test changes in product designs. Engineers designed a product component, such as an airfoil, on a computer, and then asked a modeler or sculptor to manufacture the product from clay, wood, or stock components for physical testing.
Today, the process has moved the prototyping phase much later, as the enormous growth in computational power and storage allows not only the prototyping of the entire product, but also the integration of other information. materials, components required for production, and operation of the product in the field.
“If you look at CAD and engineering tools from 30 years ago and squint a little, they’re digital twins,” says Scott Buchholz, chief technology officer and emerging technology research at Deloitte. Consultancy. “As power computing and storage increased, the ability to perform useful simulations increased, and we moved from low-end renders to high-quality simulations.”
The result is that digital twin technology is taking various industries by storm. Manufacturers of expensive vehicle and infrastructure products take advantage of the shortened design and development cycle, making aerospace companies, automakers and city planning agencies early adopters. Still, beginners adopt a simulate-first mentality to quickly iterate through product improvements.
A key advantage: digital twins pushed the physical build of prototypes much further down the design line. Nand Kochhar, vice president of automotive and transportation industries at Siemens Digital Industries Software, says some companies pursuing zero prototype initiatives are aiming to eliminate the prototyping steps altogether and enable their efforts to go straight to production.
This is a huge change from past times. “A typical product development life cycle was six to eight years,” says Kochhar for automobile manufacturing. “The industry is working on it and now they have an 18 month or 24 month life cycle. Now automobile production is more dependent on software, which has become the determining factor in its life cycle.”
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