Mechanical Transmission Control Using Digital Twin Load Estimation
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Solution Overview
Problem
Industrial electromechanical systems, such as electric drive trains, face challenges in performance optimization and health assessment due to the complexity of monitoring and controlling motor and load parameters in real-time, leading to inefficiencies and potential faults that are difficult to predict and manage.
Innovation Solution
The implementation of a digital twin system that includes real-time operational models of motors and loads, allowing for the generation of parameter estimates and control of mechanical transmission systems based on motor-load data, enabling proactive management and optimization of performance and health assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real-time monitoring and control of motor and load parameters is implemented, then system reliability and fault detection capability are improved, but device complexity and measurement difficulty increase
Solution Approach 1:
The patent creates digital twin copies of the motor and load systems that replicate their operational parameters in real-time. These digital models serve as virtual replicas that can be monitored and analyzed without adding physical complexity to the actual mechanical transmission system, thereby improving reliability while avoiding proportional increases in device complexity
Solution Approach 2:
The patent introduces digital twin models as intermediary elements between the physical motor-load system and the monitoring/control functions. These digital twins act as mediators that simplify the measurement and control processes by providing virtual representations of complex physical parameters, making them easier to monitor and analyze
2Productivity
If digital twin models are used for parameter estimation, then productivity and operational efficiency are improved, but device complexity and information processing requirements increase
Solution Approach 1:
Digital twin copies of the motor and load are created to simulate and estimate operational parameters. These virtual models enable rapid parameter estimation and performance optimization without requiring additional physical sensors or measurement devices, thereby improving productivity while keeping device complexity manageable
Solution Approach 2:
The patent replaces physical measurement and estimation mechanisms with computational digital twin models. Instead of using additional mechanical sensors or complex physical measurement systems, the digital twins perform parameter estimation through computational simulations, reducing hardware complexity while enhancing productivity
Data Source
AI summary
A method of controlling an operation of a mechanical transmission system includes receiving motor-load data corresponding to the mechanical transmission system. The method further includes receiving, by a digital motor unit, one or more motor input parameters and generating motor parameter estimates of one or more of the plurality of motor parameters. The method also includes receiving, by a digital load unit, one or more motor parameter estimates from the digital motor unit and generating load parameter estimates corresponding to one or more load parameters. The digital motor unit and the digital load unit is a real-time operational model of the motor unit and the load unit respectively. The method also includes controlling the operation of the mechanical transmission system based on one or more of the motor-load data, motor parameter estimates and load parameter estimates.