In sectors such as automotive and motor racing, this acceleration is decisive: the Dallara bodies are designed and tested with digital twins, as is the critical front wing of the Aston Martin Red Bull. Thanks to the multiphysics simulation with the digital twin of the battery model, Volkswagen Motorsport set the speed record for an electric racing car two years ago.
Another example: in an industry, higher productivity often corresponds to higher vibrations and therefore more noise.
If the digital twin is able to do an acoustic analysis, through the acoustic chambers and hotspots positioned on the tools, it will locate the noise sources, monitor them in real time and generate video maps from different colored areas to check if the system behaves correctly and, if not, suggest structural checks.
Another possible action is the modal analysis: if in the plant and / or in the production line there are cutting tools, which are subjected to vibrations and mechanical stresses, through the automated analysis of the test data the frequencies and
“natural” vibration modes to understand the reliability of the tool itself and combine with 3D analysis to see which parts are under actual stress and verify that the design is compatible with the required operating conditions.
Another problem common to industrial plants is electromagnetic interference due to the coexistence, in the production line, of electrical machines that integrate IoT devices and high voltage cables:
an electromagnetic analysis allows you to check the distribution of the magnetic field inside the single actuator, but also the dynamic performances with respect to different configurations and, if they are not optimal, to remodel the characteristics of the actuator thanks to the software material libraries.
Another need that often arises is that of guaranteeing the correct cooling of the components of a system, which often, for safety reasons, is closed, with a low air recycling rate: in this case, it is necessary to guarantee already in phase design that each
component does not overheat during the operating state, through a thermal analysis that also checks the air temperature when the system is in operation. Without digital twin, it would be necessary to build many prototypes for each variable, while with the digital twin the different parameters are tested until the right configuration is found.
During the maintenance phase, the operator can interact with the digital twin, communicate the diagnostics and evaluate the behavior of the machine / plant / production line in real time, also viewing the documents and historical data relating to what he is checking.
The strength of the digital twin is being able to guarantee all these processes together, if necessary, and monitor the entire life cycle of the product or plant, because every data received becomes an “engineering item”, an explorable, comparable “object” , traceable and usable to make decisions.
From concept to post-sales, passing through conception, engineering, process, production, logistics: with the digital twin a product / process can be validated entirely in the digital space, with a significant reduction in costs and delivery times, as well as an increase in the quality of the products / processes themselves.