By Cdr Rahul Verma (r)
In a distant galaxy and an imminent future, the objective of a digital twin becomes crystal clear. As brought out in “Rogue One: A Star Wars Story,” a pilfered digital representation of Princess Leia allowed her and rebel Commanders to pinpoint the fatal flaw in the imperial Death Star, paving the way for the annihilation mission with X-wing fighters and Jedi. The concept of a digital twin gained recognition in 2002, following a presentation by Michael Grieves hosted by Challenge Advisory at the University of Michigan. This presentation focused on the establishment of a product lifecycle management centre, encompassing elements such as real space, virtual space, and the seamless flow of data and information between the two realms. Although the terminology may have evolved over the years, the fundamental concept of creating a unified digital and physical twin has endured since its inception. While commonly believed to have originated in 2002, the roots of digital twin technology can be traced back to the 1960s when NASA employed rudimentary twinning concepts for space programming, duplicating systems on the ground to match those in space, such as in the case of Apollo 13.
In the coming years, it is anticipated that billions of objects will be represented by digital twins, software models, and physical systems. Predictions suggest that by 2027, half of large industrial companies will utilize digital twins, accompanied by approximately 21 billion digitally connected sensors. This integration holds the potential to save billions in maintenance, repair, and operation costs. By the same year, it is estimated that up to 60% of manufacturers will monitor product performance and quality through digital twins, and a similar percentage of global companies will leverage digital twins to enhance customer service experiences. The increasing prevalence of Internet of Things (IoT) sensors is driving the rise of digital twins, as these sensors provide valuable data on an object’s operation and its response to the environment, while the implementation of digital twins enhances analysis, condition simulation, operations, and overall value. Given the evident significance of digital twins, their potential for growth and utilization could extend for billions of years into the future.
Contrary to the cinematic glamour of Star Wars, real-world digital twins operate at a considerably sophisticated technical level. For instance, Tardid Technologies’ proprietary Brainbox, an AI engine, is capable of traversing a remote asset, with layers of information added to provide real-time or near-real-time status updates. This technology extends beyond science fiction, finding practical applications in everyday items like gas cylinders in our homes and million-dollar advanced vessels maintaining high pressures in extensive piping systems. The integration of IoT technology, encompassing sensors, connectivity, analytics, and cybersecurity, establishes an automatic feedback loop, enabling assets to provide updates on their status within the digital twin framework. As various systems, both new and old, are orchestrated and managed, the collaboration extends to multi-faceted teams of vendors and experts, emphasizing the intricate nature of digital twin technology.
While not a novel concept in the aerospace and defense (A&D) industry, digital twin technology is assuming an increasingly pivotal role post covid. Major aerospace original equipment manufacturers (OEMs) are actively applying digital twins across various facets of their manufacturing processes. Aastha Verma from Tardid highlights that their digital twin enables modelling, simulation, and scaling for critical stakeholders, including drone and aircraft pilots, operators, regulators, and regulatory frameworks. The A&D industry, accustomed to the challenges of a complex supply chain ecosystem subject to rigorous regulatory and certification standards, can leverage various digital twins to enhance every aspect of its value chain, from design and production to operations. The adoption of digital twin technology also promotes collaboration within ecosystems, a critical factor for success in the evolving business environment. According to Gartner, digital twins are a significant trend of the decade, surpassing the intangible metaverse. The potential growth in digital twin usage is substantial, with a predicted 36 percent surge over the next five years, and 60 percent of organizations relying on digital twins not only to improve operational performance but also to achieve their environmental goals.
A digital twin serves as a virtual replica of a physical asset, system, or process, offering the ability to monitor, model, simulate, analyze, and optimize the physical world. Bridging the physical-digital gap at the right frequency and fidelity, the digital twin enables continuous improvements to performance and sustainability. By combining data, technologies, and business processes, it creates a closed-loop methodology that uncovers hidden value and places it at the center of the Intelligent Industry transition. Digital twin technology answers questions like “what is best?”, “what if…?”, and “what next?” by predicting performance in various scenarios in addition to offering insight into present performance and recommendations for development. The application of more than one digital twin to a product or system, depending on the life-cycle stage, is possible, and these twins need not follow a monolithic model but can comprise a set of connected models representing various aspects of the real system. Digital thread and model-based systems engineering (MBSE) are closely associated with digital twins, with digital thread acting as a communication framework connecting a manufacturing company’s value chain, and MBSE facilitating the application of models to support system development.
The aerospace and defense industry, often not immediately associated with sustainability, is witnessing a transformation through digital twin technology. While major players like Airbus and Boeing anticipate a return of commercial demand in 2024, the industry is presented with an opportunity to engage in digital transformation, preparing for the new normal. Digital twin technology emerges as a key capability that can provide a foundation for future success. Embracing a sustainability agenda that extends beyond reducing aircraft emissions, the industry is adopting technologies such as digital twins for preventative maintenance, minimizing downtime, and enhancing environmental performance. A connected factory model, incorporating IoT-enabled smart meters, holds the potential to significantly improve resource and energy management during the manufacturing stage. The utilization of renewable energy at manufacturing facilities further contributes to reducing the environmental impact of production operations.
In the realm of aviation, digital twins have made significant strides in aircraft design, enabling virtual prototyping, optimized aerodynamics, improved structural enhancements, and precise maintenance methods. These digital replicas contribute to traffic flow simulations, route optimization, and adjustment of various parameters for air traffic control, presenting a futuristic yet grounded approach. The reliability of digital twins relies on a foundation of abundant, timely, and reliable data. Practical examples, such as those in the Netherlands’ Rotterdam harbor, showcase the use of digital twins to simulate tidal levels, aiding in traffic management decisions for the coming week and reducing environmental impact. Dassault Systèmes’ flexible platform for creating digital twins serves various purposes, including futuristic applications. In engineering terms, the use of digital twins minimizes reliance on probability-based techniques for maintenance predictions.
Digital twins play a crucial role in maintaining the structural integrity of aircraft, allowing engineers to analyze stress and fatigue by simulating materials and components. This data-driven approach enables informed decisions regarding materials and manufacturing processes, resulting in strengthened structures, enhanced fuel efficiency, and reduced operational expenses. Real-time monitoring within the digital twin framework, facilitated by sensors on the aircraft, proves invaluable for pilot training and decision-making. Digital twins offer realistic and immersive flight simulators, allowing pilots to practice various scenarios and emergency procedures, enhancing their skills and confidence. In the aerospace industry, digital twins have become essential tools for enhancing safety and meeting rigorous regulatory standards. Advanced simulations and risk analysis using virtual aircraft prototypes contribute to evaluating various flight scenarios, identifying safety risks, and implementing effective risk mitigation strategies. In the instance of the Dreamliner, Boeing used digital twins to closely monitor the battery system’s behavior and performance. By using digital twins, Airbus has also increased the A350 XWB aircraft’s operational efficiency. This creative approach has improved sustainability efforts by significantly reducing pollutants and fuel use. The aviation industry’s convergence of confidence and real-world application points to a bright future for digital twin technology. This development could improve sustainability and efficiency, and produce an unmatched travel experience.
Digital twins will soon become one of the most important IT technologies in the industrial sector, revolutionizing many aspects of product testing and development. As a result, nearly every manufactured good in the future may have a digital twin, provided the it creates data that can be recorded and examined. This idea, which is referred to as a “digital triplet,” will be the next development beyond the digital twin. For example, the corporation will have a unique digital model for each aircraft it manufactures, rather of having a single digital twin for development purposes of a new aircraft. Real-time data from linked sensors can be fed into these separate models, and AI analysis can.
I would like to culminate, by asserting that the aviation industry is presently experiencing a noteworthy metamorphosis through the incorporation of digital twin technology, underscoring its significance from the very inception of the design phase. The most successful businesses of tomorrow are poised to thrive by harnessing the dual forces of technology and sustainability, working in tandem. Aerospace and defense companies are urged to incorporate a conscientious sustainability strategy into their daily decision-making processes for both operational practices and product development. Despite the sophistication of contemporary three-dimensional models, interactive processing, and powerful computers, reminiscent of technology from half a century ago, the fundamental essence remains consistent. Today, we create digital twins not mere bytes and bits, but sophisticated oracles with the ability to predict the future with scientific precision. This marks a pure Industry 4.0 evolution, foreseeing machine behaviour before breakdowns occur, facilitating targeted part replacements, regulating the intricate flows of complex systems, and addressing challenges proactively in various domains to promote sustainability.
Commander Rahul Verma (r) is an Emerging Technology and Prioritization Scout for a leading Indian Multi-National Corporation, focusing on advancing force modernization through innovative technological applications and operational concepts. With 21 years as a Naval Aviator, including a distinguished role in the Indian Navy’s Technology Development Acceleration Cell, he brings diverse aviation experiences, from Sea king Pilot to RPAS Mission Commander and Flying Instructor. Through his written contributions, he aims to leverage his deep domain knowledge for the advancement of unmanned and autonomous systems, creating significant value for Atmanirbhar Bharat and the Indian aviation industry.
