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The digital twin: a game changer in product development and commissioning

The digital twin is a much-discussed topic in mechanical and plant engineering. While some companies are still evaluating the theoretical application possibilities, others are already successfully using the digital twin in practice. This applies to virtual commissioning, for example. How designers, hardware planners, electrical engineers, PLC programmers, software developers and field service technicians can actually benefit from this is shown by the example of an engineering service provider that has implemented the technology in its day-to-day business.

The digital twin and its relevance in engineering

The digital twin is not only a core element of Industry 4.0, but also a significant innovation for engineering teams. This is because it fundamentally changes the approach to the development and commissioning of products. This is made possible by its core feature: the complete mapping of a real machine in virtual space with all its details and physical properties.

The team at blue automation GmbH is well placed to assess the specific advantages of the digital twin in practice. The service provider specialises in automation technology for the automotive, supplier, pharmaceutical and medical technology and food and beverage industries. The portfolio includes hardware design and PLC software development as well as robot engineering. From its many years of project experience, the Siemens Solution Partner knows that expectations and reality can diverge greatly in the traditional approach to product development: Processes do not work as planned, the software does not fulfil all requirements, the commissioning team has difficulties understanding, extensive mechanical changes are required or there is even damage due to a crash after the start. All of these problems can be avoided if a machine or system is first tested and optimised in a virtual environment.

Significant cost and time savings possible

The blue automation approach is structured in stages. Firstly, the customer creates the 3D data of the planned system based on the mechanical design. The provider then adds the physical properties of the machine using MCD. This is necessary in order to map the behaviour, movements and interfaces of all sensors and actuators. In the next step, the resulting virtual twin is ready to be tested virtually in conjunction with the PLC control system. Every function and the entire process can therefore be evaluated in detail even before the system goes into construction. Naturally, this results in a whole range of benefits.

Firstly, virtual commissioning using the digital twin is helpful for basic feasibility and achievability analyses. It also helps to identify and rectify design errors at a very early stage. Opportunities for material and energy savings also become visible. The quality of the associated software programmes can also be significantly improved through virtual testing. All in all, these features lead to lower costs for subsequent changes, more sustainable solutions and the delivery of an optimised product - both in terms of hardware and software.

Commissioning process is also significantly improved

In addition to cost and time savings as well as significant quality improvements, the digital twin has another major advantage: field service employees can familiarise themselves with the machine or system in detail even before they travel to the end customer. This is a clear advantage, especially for complex products. Virtual testing in advance means that the actual commissioning process runs much more smoothly. This in turn not only increases customer satisfaction, who naturally welcome a scheduled and problem-free go-live. Existing personnel resources are also spared considerably. In times when there is a shortage of staff and employees are generally less willing to travel, this is also a factor that should not be underestimated.
 

Further use cases for the digital twin

As the digital twin is available with 3D data, PLC and operating elements, it can also be used to train inexperienced or new operating personnel. Compared to training on the real system, this variant is completely risk-free, as operating errors do not lead to damage. Furthermore, various error scenarios, including the respective problem solutions, can be practised.

Of course, in practice it happens time and again that a running system needs to be converted or extended. This is another area where the digital twin comes into its own. This is because it makes it possible to plan and implement the conversion virtually, adapt the software and test the overall design. The real system is only modified once this has been successfully completed. This approach significantly minimises downtimes during the conversion.

Last but not least, the digital twin is a very good visualisation of the real system thanks to the 3D modelling. It can therefore also be used for advertising purposes, at trade fairs, for customer training or as part of demonstrations by the sales team.

Advertorial published in the Handelsblatt, 28/02/2024