Modern manufacturing is an increasingly digital process. The creation and use of digital twins in manufacturing can make a business’s operations faster, more efficient, and cheaper.
What Is A Digital Twin in Manufacturing?
At its most basic, a digital twin is a virtual counterpart of a real-world object or objects. It might be a product, an assembly line, or a fleet of vehicles, but all digital twins consist of:
- A physical entity or system that the twin is replicating.
- A digital representation of the entity, such as a virtual replica created using data, 3D modeling techniques, and software algorithms.
- Data connections, such as sensors and Internet of Things (IoT) devices, that seamlessly update the digital twin with the physical object’s information.
With these elements in place, a digital twin can track its physical counterpart in real time, simulate different scenarios, and help operators plan for the future.
Applications for Digital Twins in Manufacturing
Properly implemented, digital twins can be used in a wide range of roles. In the world of manufacturing, some of the most useful are:
Product Development and Testing
Prototyping, developing, and testing new products can be a laborious and expensive process. Digital twins can reduce the time and cost of this stage by simulating how different components or devices interact with each other. This digital twin software combines real-world data from prototypes with programs that can replicate real-world scenarios. By running on an industrial-grade PC, these simulations can determine if a product will meet its performance and reliability standards or if it needs another design pass. It also helps avoid going through multiple prototypes, which helps reduce cost and development time.
Facility Planning and Construction
Constructing a new industrial facility, such as a factory or refinery, is a colossal undertaking in terms of time, money, and manpower. The last thing anyone wants is to get halfway through construction only to realize that the facility’s layout is wrong.
A digital twin of the factory’s design goes one step beyond simple blueprints. It can not only validate the layout’s design but also simulate operations. This lets designers identify potential bottlenecks or safety hazards before they ever become a real issue.
Preventative Maintenance
As any factory operator can tell you, unplanned interruptions or mechanical breakdowns can have a catastrophic effect on your bottom line. That’s why identifying mechanical issues before they spiral out of control is so critical for manufacturers. With the advanced monitoring that digital twin technology offers, workers can react to changing circumstances much more quickly.
Remote Monitoring
Because digital twins exist as computer software on a network, they can be accessed and controlled remotely, such as via an industrial panel PC. This enables remote monitoring of the physical objects they represent, such as machinery. This, in turn, reduces the need for on-site workers, which can be extremely valuable in hazardous work environments or hard-to-access areas.
Benefits of Using Digital Twins in Manufacturing
The insights and control that digital twins provide can significantly improve the performance of almost any industrial operation. The most important benefits in manufacturing are:
Easier Product Development and Refinement
With digital twins, manufacturers can test products without constantly producing physical prototypes. This saves time and money during the development stage, preventing late-stage redesigns and ensuring a faster time to market. After products reach the market and start facing real-world working conditions, digital twins can use the data they gather to further improve future versions of those products.
Real-Time Insights
By constantly monitoring equipment or machines while they’re in use, operators can collect data on a second-by-second basis. This level of visibility makes it easier to detect anomalies or patterns of behavior, which enables operators to adjust as needed. For example, if an assembly line is experiencing bottlenecks during production, digital twins can help identify where and why these issues occur. Armed with this information, manufacturers can optimize their workflows and address inefficiencies.
They can also use digital twin technology to enable off-site work and collaboration. If a machine breaks down, off-site experts can review the digital twin’s information and guide on-site employees through repairs without having to be physically present.
Predictive Analytics and Simulations
The data that digital twins gather can also be used to predict the future and simulate possible scenarios. A digital twin of a factory floor can simulate how operations are affected if a particular section of the assembly line breaks down, letting owners prepare for these scenarios.
Digital twins’ data can also be fed to generative AI to develop predictive insights. By running digital twin software on an industrial AI box PC, manufacturers can predict their maximum potential output, analyze breakdown patterns to optimize maintenance schedules, and reduce the need for human oversight.
Challenges for Using Digital Twins in Manufacturing
Like any new technology, there are hurdles to overcome for implementing digital twins in manufacturing workflows.
Performance Requirements
First and foremost, digital twin technology places a high demand on the computers it runs on. Processing the data feeds from multiple sensors monitoring a single machine is one thing. Doing the same for an entire assembly line is another altogether. Any computer managing digital twins in an industrial setting should be manufactured to a truly rugged degree to ensure performance and reliability.
Cost and Training
While the long-term benefits of digital twins cannot be overstated, some manufacturers may balk at the immediate cost, as well as the difficulties of training their workforce to use these new tools. One of the best ways to reduce these difficulties is by working with an original equipment manufacturer (OEM).
An OEM can customize your purchase to your exact needs, striking a balance between your performance requirements and your budget. They can also set your device’s image and have it arrive with all of the necessary software already installed. By using software your employees are already familiar with, you can reduce the training time needed.
Security
Massive amounts of data are transferred to and from digital twins, much of it valuable or sensitive. Any computers that work with this technology should also have strong cybersecurity features, such as trusted platform modules and access control methods. These features prevent outside intrusion and keep your information safe from prying eyes.
Digital Twin-Ready Industrial Computers from Cybernet Manufacturing
With digital twins in manufacturing, businesses can enjoy greater insight into and control over their operations than ever before. The only limitations are the processing power and reliability requirements of these tools.
If you’re looking for rugged industrial computers to support digital twins technology, contact the team at Cybernet Manufacturing. We’d be happy to explore how our industrial-grade tablets and PCs can enhance your business with the latest in digital tools.