Digital Twin Motor Dimensioning for Lifetime Energy Extrapolation

Solution Overview

Problem

Incorrect motor dimensioning leads to reduced energy efficiency, accelerated component aging, and increased maintenance needs due to excessive physical stress from operating in a suboptimal environment.

Innovation Solution

The system uses digital twins of motors to simulate industrial processes based on collected process data, estimating and extrapolating energy consumption and maintenance needs over the motor's expected total useful lifetime, allowing for the selection of a more optimally suited motor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If motor dimensioning is performed without simulation and extrapolation, then the process is simple and quick, but energy efficiency is reduced and component aging accelerates

Engineering Contradiction:

Improveenergy efficiencyVSAvoidcomplexity of motor selection process

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The system performs preliminary simulation and extrapolation analysis before final motor selection. By using digital twins to simulate motor performance under various operating conditions and extrapolating energy consumption over the motor's total useful lifetime, the system enables informed motor dimensioning that optimizes energy efficiency while accounting for long-term operational characteristics.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates digital twin copies of motors to simulate and analyze performance without requiring physical prototypes or extended trial operations. These virtual replicas allow comprehensive evaluation of energy consumption, maintenance needs, and performance characteristics under different operating scenarios, enabling optimal motor selection before actual deployment.

Inventive Principle:

Principle #26Copying

2Duration of action of stationary object

If motor dimensioning is performed without simulation and extrapolation, then the process is simple and quick, but component aging accelerates due to excessive physical stress

Engineering Contradiction:

Improvemotor useful lifetimeVSAvoidcomplexity of motor selection process

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The system performs preliminary simulation and extrapolation analysis before final motor selection. By using digital twins to simulate motor performance under various operating conditions and extrapolating energy consumption over the motor's total useful lifetime, the system enables informed motor dimensioning that optimizes energy efficiency while accounting for long-term operational characteristics.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system anticipates and prevents excessive physical stress by simulating operating conditions and identifying potential stressors before the motor is deployed. By analyzing maintenance needs and performance degradation patterns through digital twin simulations, the system selects motors that are appropriately dimensioned to withstand expected operational stresses, thereby extending component lifetime and reducing premature aging.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Loss of time

If traditional motor selection is used, then initial commissioning is faster, but long-term energy consumption is higher

Engineering Contradiction:

Improvetime for motor selectionVSAvoidlong-term energy consumption

Core Design Contradiction:

Loss of timeVSLoss of energy

Solution Approach 1:

The system performs preliminary simulation and extrapolation analysis before final motor selection. By using digital twins to simulate motor performance under various operating conditions and extrapolating energy consumption over the motor's total useful lifetime, the system enables informed motor dimensioning that optimizes energy efficiency while accounting for long-term operational characteristics.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system evaluates multiple motor options with different parameters (power ratings, efficiency classes, operational characteristics) by simulating their performance under actual operating conditions. By changing and comparing key parameters such as energy consumption, maintenance intervals, and performance metrics across different motor candidates, the system identifies the optimal balance between initial commissioning time and long-term energy efficiency.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4180890B1Extrapolating motor energy consumption based on digital twin

Publication Date: 2025.03.05 ABB (SCHWEIZ) AG

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AI summary

Disclosed is a method comprising obtaining a set of process data associated with an industrial process, wherein the set of process data comprises measured values associated with the industrial process over a time period; estimating at least an energy consumption of each motor of a plurality motors over the time period based at least partly on the set of process data and a plurality of digital twins associated with the plurality of motors, wherein the plurality of digital twins comprises at least a first digital twin of a first motor and a second digital twin of a second motor different to the first motor; extrapolating at least the energy consumption of each motor of the plurality of motors over an expected total useful lifetime of each motor; and indicating at least the extrapolated energy consumption of each motor of the plurality of motors.