Digital Twin Feedback Control for Adaptive Manufacturing

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Solution Overview

Problem

Conventional additive or subtractive manufacturing processes rely on user experience or rudimentary simulations, leading to inefficient trial-and-error adjustments when unexpected events occur, resulting in uncertain production outcomes due to oversimplified variable handling.

Innovation Solution

Implementing digital twins to model and simulate manufacturing processes, allowing for real-time feedback and optimization of production parameters based on actual physical production data, thereby reducing the need for trial-and-error adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional manufacturing methods with user experience or rudimentary simulation are used, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to oversimplified variable handling

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidproduction parameter accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent creates a digital twin (virtual copy) of the physical manufacturing system that includes a virtual model of the manufacturing process, materials, and equipment. This digital replica allows for sophisticated simulation and analysis without adding physical complexity, enabling precise parameter optimization through virtual experimentation before actual production.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The system performs preliminary simulation and analysis in the digital twin environment before actual manufacturing. By predicting potential issues and optimizing parameters in advance through virtual testing, the system avoids trial-and-error in physical production, thereby improving manufacturing precision without proportionally increasing device complexity.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If trial-and-error adjustments are made when unexpected events occur, then adaptability is improved, but productivity deteriorates due to inefficient rework and termination of jobs

Engineering Contradiction:

Improveprocess adjustment capabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent implements a feedback mechanism where sensors monitor the physical manufacturing process in real-time and transmit data to the digital twin. When deviations or unexpected events are detected, the system automatically adjusts parameters by comparing actual performance with virtual predictions and applying corrective actions, enabling adaptive response without stopping production and maintaining high productivity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The digital twin system autonomously monitors, analyzes, and adjusts manufacturing parameters without requiring manual intervention. When unexpected events occur, the system self-corrects by terminating problematic jobs and restarting with optimized parameters automatically, improving both adaptability and productivity by eliminating inefficient human trial-and-error cycles.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If comprehensive simulation of manufacturing processes is implemented, then manufacturing precision is improved, but use of energy and computational resources increases

Engineering Contradiction:

Improveproduction outcome reliabilityVSAvoidcomputational resource consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies simulation and analysis selectively to critical process parameters and key stages of manufacturing rather than comprehensively modeling every aspect. By focusing computational resources on the most influential variables that impact production outcomes, the system achieves high manufacturing precision while minimizing energy and computational resource consumption.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12377610B2Manufacturing methods and systems including digital twin managing process, lifecycle, and instance

Publication Date: 2025.08.05 XEROX CORP

AI summary

This disclosure provides techniques for manufacturing parts using digital twin(s) to manage various aspects of the manufacturing system. An example method may include representing a manufacturing system using a digital twin. In some cases, representing the manufacturing system includes modeling, in the digital twin, digital representations that correspond to a number of physical components of the manufacturing system. The physical components include at least: a manufacturing material, a working environment for deposition of the manufacturing material (e.g., for additive manufacturing), a tool to manipulate the manufacturing material between at least two matter states in the working environment, and sensors measuring behaviors of the tool, the working environment, and the manufacturing material. The method may further include receiving a manufacturing production task. The task may include a digital model of a part to be manufactured and default parameters for the manufacturing material(s), the working environment, and the tool.