Digital Twin Difference Detection in Automated Installations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Differences between automated installations and their digital twins often arise due to local conditions or inaccuracies in assembly specifications, leading to significant manual effort in maintaining consistency, especially when expansions or changes occur in the real installation without updating the digital twin.
Innovation Solution
A method and apparatus involving a sensor unit fastened to process material to continuously record measurement variables, comparing these with simulated variables from the digital twin, and identifying differences by analyzing temporal profiles to locate discrepancies within the automated installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection and comparison methods are used to verify consistency between real installation and digital twin, then measurement precision can be maintained, but loss of time and productivity decrease significantly
Solution Approach 1:
The patent creates a virtual sensor unit as a digital copy of the real sensor unit. This virtual copy records virtual measurement variables that are then compared with real measurement variables from the physical sensor unit, enabling automated verification of consistency between the real installation and its digital twin without manual inspection
Solution Approach 2:
The patent replaces the manual mechanical inspection process with an automated computational system. The control unit automatically records, compares, and evaluates measurement variables from both real and virtual sensor units, substituting human expert analysis with automated data processing and deviation detection algorithms
2Manufacturing precision
If digital twin is updated manually after changes in real installation, then manufacturing precision can be maintained, but loss of time increases and productivity decreases
Solution Approach 1:
The patent implements a feedback mechanism where the control unit continuously compares real measurement variables from the sensor unit with virtual measurement variables from the virtual sensor unit. When deviations are detected, the system automatically identifies the affected areas and triggers updates to the digital twin, ensuring continuous synchronization without manual intervention
Solution Approach 2:
The patent performs preliminary actions by continuously monitoring and comparing measurement variables in real-time during installation and operation. This continuous preliminary detection of deviations allows the digital twin to be updated proactively before inconsistencies affect production, rather than waiting for manual verification
3Productivity
If automated sensor unit is deployed to record measurement variables, then productivity and speed improve, but device complexity increases
Solution Approach 1:
The patent makes the sensor unit and control unit multi-functional by enabling them to perform both real-time measurement recording and automated comparison evaluation functions. The same hardware infrastructure supports multiple operations including data acquisition, virtual twin synchronization, deviation detection, and automatic update triggering, reducing overall system complexity despite increased functionality
Data Source
AI summary
A method and apparatus for determining differences between an automated installation and a digital twin of the automated installation and to an automated installation that includes the apparatus, wherein a sensor unit is fastened to a process material and passes through an automated installation together with the process material where, during this process, the sensor unit continuously records at least one measurement variable, a temporal profile of the recorded measurement variable is compared with a temporal profile of a corresponding simulated measurement variable and if there is a difference between the temporal profiles, then the location in the automated installation at which the difference is present is identified.