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Digital TwinAn Engineers’ PerspectiveFatma Kocer – Altair – Engineering Analytics
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair at a GlanceAltair’s Vision
5,000 Customer Installations Worldwide
Long heritage of solving some of the most challenging engineering problems
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
A digital replica of physical assets, processes and systems that can be used for various purposes
Digital Twin Definition
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FunctionalRequirements
System
Subassembly
Detailed Design
ReleaseCandidate
Integration
Unit
End of Life
Physical
Digital
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• 1D models
• Fast Model Build• Multi-Model • Multi-Physics• Optimization
• Detailed Model Build• Test Coverage• Accurate Physics
In Service
Product Lifecycle and Digital Twins
• IoT Sensors • Monitoring• Maintenance• Warranty
ConceptFormulation
Product Release & Manufacturing
Feedback
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Twins for Operations
Data-Based ModelsPhysics-Based 1D Models
Detect Predict
Operation
Simulation in Digital Twins
Concept Design
Physics-Based 1D Models
IdeateOptimize
Configuration
Twins for Manufacturing
Physics-Based 3D Models
PredictPrescribe
Process/Integration
Twins for Design
Physics-Based 3D Models
Predict - SimulatePrescribe - Optimize
Detailed Design
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Twins for Operations
Data-Based ModelsPhysics-Based 1D Models
Detect Predict
Operation
Simulation in Digital Twins
Concept Design
Physics-Based 1D Models
IdeateOptimize
Configuration
Twins for Manufacturing
Physics-Based 3D Models
PredictPrescribe
Process
Twins for Design
Physics-Based 3D Models
Predict - SimulatePrescribe - Optimize
Detailed Design
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Twins for Operations
Data-Based ModelsPhysics-Based 1D Models
Detect Predict
Operation
Simulation in Digital Twins
Concept Design
Physics-Based 1D Models
IdeateOptimize
Configuration
Twins for Manufacturing
Physics-Based 3D Models
PredictPrescribe
Process
Twins for Design
Physics-Based 3D Models
Predict - SimulatePrescribe - Optimize
Detailed Design
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Predict Remaining Useful Life on an Aircraft Engine
PHM08 Challenge - NASA Challenge DataPrognostics Center of Excellence Data Repositoryhttps://ti.arc.nasa.gov/tech/dash/groups/pcoe/prognostic-data-repository/
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Problem Statement
Engine 1
Engine 2
Engine 3
Engine 100
.
.
.
TUL = 192
TUL = 245
TUL = 135
TUL = 212
Engine 101
Engine 102
Engine 103
Engine n
.
.
.
RUL = ? given 31 cycles
RUL = ? given 49 cycles
RUL = ? given 112 cycles
RUL = ? given 317 cycles
Given 20k+ data of Find
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Steps
1. Problem Formulation: • Define and compute Remaining Useful Life (RUL).
2. Data Analysis: • Review the data. • Eliminate constant values, review outliers, review relations.
3. Predictive Modelling : • Start from a simple model; then move on to more complex models.• Review diagnostics and pick the best predictive model.
4. Predict:• Use the predictive model to predict the next engine RUL.• Approximate the prediction.
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Results
• FAST for Automated Predictive Modelling• Evaluate each engine in operation using FAST
Engine No.
CurrentCycle
Actual RUL (cycles)
Predicted RUL (cycles)
101 31 112 171102 49 98 139103 126 69 65104 106 82 81124 186 20 19125 48 145 160134 395 7 11
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
DIGITAL TWIN OF A RADAR SYSTEMLIVIO MARIANO, Technical Specialist, Math and Systems
THIERRY BERNARD, Sr Technical Specialist, MBD
ALTAIR ENGINEERING2018
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TWINS for DESIGN
Mechanical Fluid ControlElectromagneticlow-frequency
Electromagnetichigh-frequency
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TWINS for OPERATION
ControlControl
SENSOR
Thermal
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
IoT Platform
TWINS for OPERATION
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
USE CASE : MAINTENANCE RECOMMENDATION
Data collection and storage(current/historical)
Real-timeanalysis
FRICTION IS HIGH
Lubrication is contaminated. Schedule maintenance
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
USE CASE : MAINTENANCE RECOMMENDATION
Data collection and storage(current/historical)
Real-time analysis
ANOMALIES in SENSOR 21
Sensor 21 is the acceleration sensor in the antenna.
Check the antenna structural integrity
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
USE CASE : PERFORMANCE PREDICTION
Combined with external data, 1D models are run for performance predictions against future events such as extreme weather events.
Based on these predictions, feedback to the system are given such as optimized operation settings or suggested maintenance.
Data collection and storage(weather data)
Feedback to the system
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
USE CASE : PARAMETER UPDATE
Calculated Motor Torque
USE CASE : PARAMETER UPDATE
Virtual model does not match to physical model.
Automatically update the friction parameter values.
Update friction coefficients
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
USE CASE : CALIBRATION of the DIGITAL TWIN
Data collection and storage(current/historical)
Real-timeanalysis
INACCURATE DIGITAL TWIN
Virtual model no longer matches to physical model.
Use optimization to calibrate the model.
Optimization for calibration
Update the model
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
USE CASE : DESIGN FEEDBACK
Data collection and storage(current/historical)
Real-timeanalysis
Trends are found for each location, design.
Give feedback to design, maintenance.
© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
ALTAIR’S OFFERINGSALTAIR’S OFFERINGS
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Simulation Driven Design
Top-tier consulting expertise
HyperWorks®
Digital Twin Simulation
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IoT and Analytics