Digital Twin Configuration for Real-Time Machine Tool Optimization
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Solution Overview
Problem
Determining the optimal configuration of industrial assets like machine tools is complex due to the need for continuous monitoring of performance and the complexity of combining components and parameters based on machining operations, which existing technologies fail to address effectively in real-time.
Innovation Solution
A system and method using digital twins, where a first digital twin stores historical data and failure predictions, and a second digital twin is configured based on real-time operating parameters to simulate and replicate the asset's behavior, allowing for reconfiguration to optimize performance by comparing simulated results to threshold values and updating knowledge databases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous monitoring and real-time optimization of machine tool configuration is implemented, then performance optimization and operational efficiency are improved, but system complexity and computational requirements increase
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the machine tool that replicates its behavior and configuration. This digital replica allows real-time simulation and optimization without affecting the physical system, enabling continuous monitoring and performance optimization while avoiding the complexity of directly modifying the physical machine tool during operation.
Solution Approach 2:
The system performs preliminary simulations and optimizations in the digital twin environment before applying changes to the actual machine tool. By pre-evaluating configuration changes virtually, the system identifies optimal settings in advance, reducing the need for complex real-time adjustments and minimizing disruption to production operations.
2Reliability
If digital twin simulation and reconfiguration are performed in real-time, then performance optimization is improved, but computational time and processing requirements increase
Solution Approach 1:
The system performs simulations and optimizations selectively based on operational needs rather than continuously at full capacity. By applying partial optimization actions only when necessary or when significant improvements are expected, the system maintains high reliability without requiring excessive computational time for every operational state.
3Measurement precision
If multiple components and parameters are combined to determine optimal configuration, then configuration accuracy is improved, but determination complexity increases
Solution Approach 1:
The patent breaks down the complex configuration determination into manageable segments by creating a digital twin that separately models different components and parameters of the machine tool. This segmentation allows systematic analysis and optimization of individual elements while maintaining overall configuration accuracy, reducing the cognitive and computational burden of handling all parameters simultaneously.
Data Source
AI summary
A system, apparatus and method for determining operational configuration of asset are provided. The method includes receiving a set of operating parameters associated with the asset, identifying data associated with the asset based on the received set of operating parameters, configuring a second digital twin of the asset based on the data identified from first knowledge database, simulating a behavior of the asset based on the configured second digital twin in a simulation environment, and determining an operational configuration associated with the variant of the asset based on results of the simulation.