BimScaler Blog – Digital twins in engineering are more than just 3D models. They’re dynamic, data-driven simulations that mirror how their real-world counterparts behave.
Yep, engineers can use digital twins to test out different scenarios, see what will happen, and make sure everything is working as it should without having to build a physical prototype or do tests.
Simply put, digital twins are changing the way engineers design, test and manage complex systems.
That’s why we need to get into the nitty-gritty here. Right, let’s get started.
Importance of Digital Twins in Modern Engineering
Digital twins technology is all about creating a virtual copy of a physical object, system, or process. This lets engineers test, monitor, and tweak designs in real time.
By replicating real-world conditions in a virtual environment, digital twins help us make better forecasts and manage our resources more effectively. This leads to cost savings and improvements in performance.
That’s why digital twins are great for helping with decision-making.
They give engineers real-time, data-driven insights into physical systems, helping them to spot potential issues, test solutions and implement changes effectively.
As the AVEVA team said in “The Big Dig: “Evolving Digital Tools to Overcome Challenges from Pit to Port,” using engineering data throughout a facility’s lifecycle creates a feedback loop for continuous improvement, which results in better facility operations.
Another great thing about digital twins is how the technology can help you save money.
As an example. Boeing uses digital twins to simulate and optimize aircraft assembly processes, which has led to some pretty big cost savings.
Using digital twins means you don’t need to make physical prototypes or do lots of physical testing, which saves on materials and labour costs.
If you can predict and address issues before they arise, you can also minimize downtime and maintenance costs.
Digital twins also help with predictive maintenance by keeping an eye on how equipment and systems are doing.
In their report, “Outperform your competition with a comprehensive digital twin,” Siemens used digital twins to help Hugo Back reduce energy consumption by up to 20%, packaging material by up to 30%, and packaging volume by 10%. They also replaced plastic film with more easily recyclable paper.
This proactive approach not only makes assets last longer but also makes them more reliable.
For specific information on Azure products, kindly check “More Profit, Less Hassle: The Azure Digital Twins Guide for Busy Leaders.”
Applications of Digital Twins in Engineering
Product Design and Development
In product design, digital twins let you create virtual prototypes, which saves time and money compared to making physical prototypes.
Automotive companies like General Motors use digital twins to test new car models under different conditions before they start making them in real life.
This approach helps us spot and fix any design issues early on, which means we can make better products and get them to market faster.
Manufacturing and Production
In manufacturing, digital twins are used to keep an eye on and make improvements to production processes.
They can simulate production lines, spot inefficiencies and suggest improvements.
GE Digital’s Operations Performance Management software creates digital twins of processes and assets to help team members get a better idea of what plant capacity and heat rate they can expect on any given day.
This helps Competitive Power Ventures (CPV) to make the most profitable use of that capacity by improving how they prepare for commitments, nominate fuel and plan their dispatch.
This real-time optimisation ensures we make the most of our resources and get the best out of our overall productivity.
Infrastructure and Construction
In the world of infrastructure, digital twins are great for helping with planning, construction and maintenance of buildings and other structures.
The New South Wales Government’s Spatial Digital Twin project in Australia is a great example of how data on transport, utilities, and buildings can be used to improve urban planning and infrastructure management.
This detailed digital model helps everyone involved to work together more effectively and get the job done more efficiently.
Energy and Utilities
In the energy sector, digital twins help us to generate, distribute and consume energy more efficiently.
They help manage energy grids, predict equipment failures, and improve efficiency.
Beijing Aero-Top Hi-Tech uses digital twins to keep an eye on and make improvements to urban pipeline networks in real time.
This helps them run their operations more efficiently and safely.
Challenges and Limitations
One of the main problems is getting all the data to work together. If you want to integrate data from different sources in real-time, you need a solid infrastructure.
The problem is made worse by the fact that the source data systems are all different.
So, it is getting harder to keep the data in digital twins up to date and of good enough quality.
Another big challenge is getting the models right. Making sure that digital twins accurately reflect their physical counterparts is fundamental for them to work well.
If there are any differences between the model and the actual system, it could lead to wrong predictions and decisions, which could cause problems with operations.
Security and privacy concerns are also a big issue. It’s vital to keep the data used and generated by digital twins safe, especially in sensitive industries like healthcare and defence.
Given the risk of data breaches and cyberattacks, it’s important to have advanced security measures in place to protect this valuable information.
Another hurdle is the cost of implementation, which can be a challenge for smaller companies.
Creating and maintaining digital twins can be pricey. You have to invest a lot in software, hardware, and skilled personnel.
This can be a real stumbling block for smaller companies, who often lack the resources to make the investment.
If you want to know more, have a look at “Digital Twins in Manufacturing: Why Your Rivals Use It & You Don’t?“
What is an Example of a Digital Twin in Engineering?
One great example of a digital twin in engineering is how it’s used in aircraft maintenance by Rolls-Royce.
With a digital twin, Rolls-Royce can study and predict how an engine would behave in the most extreme conditions.
This lets Rolls-Royce model potential operational scenarios completely digitally.
The ability to map complex real-life scenarios on a virtual platform allows Rolls-Royce to make improvements and adjustments to operations, as well as maintain our highly complex aero engines even more effectively.
Digital twinning is part of a whole bunch of digital models that underpin the IntelligentEngine, our vision for the future.
The IntelligentEngine vision also means that Rolls-Royce can design, test and maintain engines in the digital twin environment.
In the future, engines will be connected, contextually aware and able to understand, which will help us deliver products that are more reliable and efficient.
We also suggest you have a look at Serge Zacher’s paper for the South Florida Journal of Development, called “Digital Twins by Study and Engineering.”
How to Get a Support System for Your Digital Twins Engineering Projects
Making the switch to digital twins in engineering can be tough, especially for companies that aren’t familiar with the technology.
Some of the problems that can get in the way of adopting digital twins are things like data integration, model accuracy and cost.
At BIM Scaler, we’re all about CAD and BIM management. We’ve got the know-how to make digital twins easier to integrate and manage in engineering projects.
Our expert team will work with you to create and maintain accurate, impactful digital twins that align perfectly with your goals.
This also means you won’t have to worry about any disruption and can start reaping the benefits of this transformative technology pretty quickly.
The great thing is that you can see what’s going on with your assets in real time, so you can spot and fix any problems before they get worse.
This proactive approach helps you avoid any downtime, make your operations more efficient and save money.
Let’s get started with a background check. So, kindly visit and read our BIM Management Support page here.
Or if you’re interested in talking further, just drop us an email or give us a call today to make a lunch meeting appointment. We’d love to show you what we can do for you.
In Closing
While there are some challenges, the potential benefits in terms of efficiency, innovation, and risk mitigation are huge.
But here’s the thing: the future of engineering is digital, and digital twins are leading the way.
That’s why, with the BIM Scaler support system, you can implement and manage digital twins in engineering to gain benefits for your operations and strategy.
