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Approach to Twinning with High Twinning Rates: Enabling the Use of Data-Driven Methods for Digital Twins

Digital twins are used in product development to evaluate and improve system reliability. The synchronization of data between the physical and virtual worlds, also called twinning, is an elementary part of the digital twin. Virtual-to-physical (V2P) twinning enables predictive maintenance, model predictive controls, and the optimization of the product. Physical-to-virtual (P2V) twinning enables model updating, fault diagnostics, and failure prognostics. The twinning rate, described as the update frequency of the synchronization, has to be quite high in dynamic systems. Otherwise, deviations between the physical and virtual worlds will be detected too late, making investigations using the twinning methods unnecessary. However, it is unclear how twinning can be realized for performance tests with real-time synchronization with a high twinning rate and high fidelity of the digital twin model. The aim of this work is to describe an approach to twinning with high twinning rates (> 1 kHz) to enable the use of data-driven methods for digital twins. For this investigation, a single case study was carried out using an electro-hydraulic actuator (EHA). The EHA consists of a double-acting hydraulic cylinder, an internal gear pump, and a permanent-magnet synchronous machine. The high dynamics of the EHA require a high twinning rate. The digital twin model in this work is a multiphysics model. It is created with MATLAB 2020a using the extension Simulink. The simulation model of the digital twin is explained in detail. Two real-time computers Adwin-Pro2 were used. One computer is running the simulation, the other is controlling the test bench and acquiring the measured data. EtherCAT, an Ethernet-based fieldbus system, is used to transfer data between the physical and virtual worlds. A Beckhoff PLC is managing the communication and performs the synchronization. To validate the approach, various tests were carried out. Performance tests were conducted to evaluate the synchronization of the physical and virtual data. The result of the case study is that the approach with the described digital twin, the two real-time computers, and EtherCAT for communication is applicable for twinning with high twinning rates. For a better evaluation, an uncertainty quantification (UQ) has to be carried out in the future. The so far successful application in the case study shows that the implemented approach can be used for twinning with high twinning rates. This enables the use of data-driven methods for digital twins in product development. The system reliability can thus be evaluated or even improved.

Document Details

ReferenceNWC23-0348-presentation
AuthorsLeitenberger. F Dörr. M Gwosch. T Matthiesen. S
LanguageEnglish
TypePresentation
Date 17th May 2023
OrganisationKarlsruhe Institute of Technology
RegionGlobal

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