What is a Digital Twin?

A digital twin is a digital model of a physical object. The physical object has sensors which send data to the digital model. The digital model is used to understand and analyze the performance of a particular machine or system.

A CAD model is essentially a computer model of a thing to be built - the model is not connected or responding in any way to the real world. A digital twin, on the other hand, incorporates real-time data from the physical world through sensors in the real model. In this way the digital and physical are connected. 

An emerging application of digital twins is in the aircraft engine industry. Engine manufacturer GE (General Electric) is developing digital twins of the engines it manufactures. Built into each engine are hundreds of sensors that record data about the temperature, stress, fuel consumption, speed, and other forces and factors. This data is continuously transmitted and incorporated into a digital twin of that unique engine. GE is able to monitor the performance of the engine and use this data to improve the performance, efficiency, as well as identify potential problems, all in real time. If they identify an issue in the digital model, they can alert the aircraft maintenance crew to investigate or repair it. In this way, they are able to optimize maintenance and reduce costly unplanned repair and downtime.

Other examples of digital twins include power generation, wind turbines, and even the city of Singapore. Each of these complex systems uses hundreds or thousands of sensors and data points to continually update a digital model. 

Features of Digital Twins

• Sensors collect data which is incorporated into the digital model.

• Sensors are part of the physical design.

• The digital model is continuously updated with sensor data

• Internet of Things (IoT) technology to connects the physical object to the digital model.

Application of Digital Twins

• Used in complex, high performance systems where maintenance and downtime must be managed carefully or minimized

• Predict wear and tear on engine components

• Continuous monitoring can be used to Identify early any possible failure

• Identify possible areas for improvement of efficiency

• Improve the maintenance and repair of cycle of equipment or machines.

1. Describe the role of sensors and data in a digital twin system.

2. Outline the benefits to an airline  of using a digital twin for an aircraft engine.

3. Describe the key differences between a digital CAD model and a digital twin model.

4. What might be some of the disadvantages and challenges of a manufacturer using a digital twin?

5. Outline the drawbacks of using any digital model to represent the physical world.

6. Outline how a digital twin can be incorporated into a quality management process.

Digital Twins are typically implemented in large scale, complex, high performance systems such as those described above. However,  IoT makes it possible and affordable to attach sensors and manage data with ever increasing ease.

• GE: Digital Twins

• Forbes Magazine: 7 Examples of Digital Twins

• Deloitte Insights: Industry 4.0 and the Digital Twin