Digital Twin Electrode Structure With Process-Based Consistency Verification
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Solution Overview
Problem
Existing methods for forming digital twin electrode structures face challenges in achieving high consistency with real objects due to time-consuming specimen preparation and deformation during cutting, leading to discrepancies in cross-sections and requiring extensive experimental validation.
Innovation Solution
A method involving a first program to simulate the manufacturing process of a target electrode structure using a discrete element method, followed by a second program to model contact interfaces using a finite volume method, with a verification step to ensure consistency, including mechanical and electrical characteristics, to form a digital twin electrode structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If 3D reconstruction is used to form a digital twin electrode structure, then the similarity with the actual sample is improved, but the manufacturing time and complexity increase significantly
Solution Approach 1:
The patent creates a digital copy (digital twin) of the electrode structure through computational modeling rather than physical replication. The system generates a three-dimensional model by processing two-dimensional image data and manufacturing parameters, producing a virtual replica that captures the essential structural characteristics without requiring extensive physical specimen preparation and imaging
Solution Approach 2:
The patent incorporates manufacturing parameters and process information into the digital twin creation process beforehand. By integrating data about the manufacturing process, material properties, and design specifications during the modeling phase, the system prepares the digital representation in advance with built-in accuracy, eliminating the need for post-processing validation through extensive physical experimentation
2Manufacturing precision
If 3D reconstruction is used to form a digital twin electrode structure, then the similarity with the actual sample is improved, but the process complexity increases
Solution Approach 1:
The patent employs a multi-functional computational system that integrates multiple capabilities into a unified digital twin creation process. The system simultaneously handles image processing, three-dimensional reconstruction, manufacturing parameter integration, and structural modeling within a single computational framework, eliminating the need for separate specialized equipment and processes for each function
Solution Approach 2:
The patent uses computational algorithms and software as intermediaries to bridge the gap between two-dimensional image data and three-dimensional structural representation. Rather than requiring direct physical measurement and manual reconstruction, the system employs computational mediators that automatically transform raw image data into accurate three-dimensional models, simplifying the overall process
3Measurement precision
If physical specimen cutting is used for 3D reconstruction, then the digital twin accuracy is improved, but the specimen deformation occurs
Solution Approach 1:
The patent replaces mechanical specimen cutting and physical imaging with computational modeling methods. Instead of physically sectioning the electrode specimen and imaging each cross-section, the system uses computational algorithms to reconstruct the three-dimensional structure from external observations and manufacturing data, eliminating mechanical interference with the specimen
Solution Approach 2:
The patent creates a digital copy of the specimen structure through computational reconstruction rather than physical sectioning. The digital twin is generated by processing image data and manufacturing parameters to build a virtual model that accurately represents the original specimen's three-dimensional structure without requiring physical disruption of the specimen itself
Data Source
AI summary
A method of forming a digital twin electrode structure reflecting an electrode manufacturing process, including modeling a digital twin electrode structure by simulating a process of manufacturing an electrode that is the target of a digital twin and comparing mechanical and/or electrical characteristics thereof with those of the target electrode, thereby increasing consistency of the digital twin electrode structure. The method involves collecting parameters of the target electrode structure, simulating material behavior using a discrete element method, and refining the model using a finite volume method to incorporate particle contact interface characteristics. The system for forming and verifying the digital twin electrode structure includes a verification module that compares the characteristics of the digital twin electrode with the target electrode, and a feedback mechanism to adjust the model based on deviations identified during the verification process, ensuring a close match between the digital twin and the target electrode structure.