August 01, 2024
By: PhoenixBizz Staff Writer
PhoenixBizz is a division of Sofvue, LLC
Printed with permission of Data Titan and Sofvue LLC
Technological revolutions never cease to amaze us. From self-driving cars to drones, technology powers everything around us. Mechanical and electrical engineers are always under pressure to create high-end working models. Designing a mechanical model is no easy task. The process is complex and requires expertise. However, the difficulty becomes less burdensome when we combine an engineer's expertise with innovative technology, such as that found with digital twins.
Professionals working in or owning mechanical and electrical firms are familiar with digital twin technology. This article will explore how engineering businesses can use this technology in apps and software to predict and prevent equipment failure. We will also look at its many benefits and key considerations.
What is Digital Twin Technology?
Digital twin technology is used to create digital copies of any object or machinery. It provides a detailed analysis of equipment design by studying a virtual prototype, showing how the object will look and function in real life. Real-time data and machine learning algorithms make this innovation possible, revolutionizing the engineering sector. Mechanical engineers use this technology to create detailed prototypes of their designs, which help in deciding the future course of action and predicting possible equipment failures.
Engineers can determine if a model will work in real life. With digital twin technology, they can identify and fix loopholes. It also makes equipment failure prediction quick and accurate. Today, even NASA uses digital twins to develop recommendations, roadmaps, and better-quality aircraft.
Impact of Equipment Failures on Engineering Business
Forbes found that an average manufacturer or business is confronted with as much as eight hundred hours of equipment downtime per year. Fixing these issues is now a costly procedure. These costs include repairs and the loss incurred due to production-line halts. Equipment failure is a significant bottleneck that affects production in any business, leading to substantial losses. Imagine utilizing these funds somewhere else to maximize profits.
Digital Technology to Predict and Prevent Equipment Failure
As mentioned before, digital twins provide a detailed view of a model, helping companies save money by reducing equipment downtime. This technology connects the virtual and physical worlds. Here are the main benefits of digital twins:
#1. Detailed Design Analysis
Digital twins enhance equipment design and usage. Engineers use digital twins to replicate real objects, test operational conditions, and conduct experiments. This allows them to study the design in detail to find and fix errors or weaknesses that could cause failure. For example, in building large industrial machinery, a digital twin can simulate the effects of constant use, helping designers strengthen vulnerable parts and improve the machinery before manufacturing begins. This proactive approach reduces the chances of costly breakdowns in the future, ensuring well-built equipment.
#2. Timely Detection of Bottlenecks
One of the best benefits of digital twins is their ability to automatically find bottlenecks. These obstacles often disrupt systems, reduce productivity, speed up wear and tear, and cause targets to be missed. Digital twins analyze data from sensors on the equipment to pinpoint areas of low performance.
#3. Real-Time Monitoring
Real-time monitoring is a key part of digital twins. Information on factors like temperature, pressure, vibrations, and speed is analyzed to check the equipment's condition. The digital twin mirrors the physical equipment, providing a real-time view of its status. This continuous dataflow quickly detects any issues. For example, a sudden rise in temperature or unusual vibrations can signal a problem, prompting maintenance teams to act before a failure occurs. Real-time assessment ensures the equipment operates under optimal conditions, enhancing reliability and durability.
#4. Condition-Based Maintenance
Traditional maintenance relies on set schedules, regardless of the equipment's actual condition. Digital twins, however, enable condition-based maintenance, where actions are taken based on the equipment's current state. By comparing real-time data with historical information, a digital twin can determine when maintenance is needed. For example, if a part is wearing out faster than normal, the digital twin can suggest replacing it before it fails. This proactive approach prevents unnecessary breakdowns, reduces downtime, and extends the equipment's lifespan.
#5. On-Site Testing
Digital twins allow for on-site testing without disrupting the equipment's main operations. Engineers can conduct various tests and explore maintenance options using the digital model. For instance, they can evaluate performance changes by altering operational settings or adding new components. This testing capability helps optimize maintenance processes and ensures that any changes will not harm the equipment's efficiency. On-site testing saves time and provides valuable insights into the machinery's operations and functionality.
#6. Efficient Performance
Digital twins help boost productivity by controlling and enhancing equipment performance. They manage operational factors in real-time using collected data. For example, in designing a new engine for a sports car, a digital twin can control elements like temperature and power to conserve energy and ensure thermal comfort. This dynamic optimization reduces energy use, minimizes component wear, and improves overall operational effectiveness. Real-time management ensures optimal uptime and high performance throughout the equipment's service life.
#7. Long-Term Cost Savings
The analytical and proactive features of digital twins lead to significant long-term cost savings. By addressing potential issues before they develop, digital twins prevent costly breakdowns and emergency maintenance. They also reduce maintenance costs and extend the equipment's operational life. Experts believe that improved performance through digital twins results in energy conservation and lower operational overhead.
You may also like to read: The use of Building Information Modeling (BIM) Software for Collaborative and Integrated Design Processes in Engineering Firms
Benefits of Using Digital Technology in Software
Custom software development companies use digital twin technology to help businesses predict equipment failures in advance. They create software and mobile apps with digital twins to closely monitor designs, models, or prototypes, predicting and preventing equipment failures.
Here is how it is done:
1. Data Collection
Digital twin-driven mobile apps allow engineers and testers to gather detailed data. This data helps study the deeper aspects of equipment design, ensuring it remains in good condition.
2. Instant Alerts
These apps send timely updates and alerts to relevant departments whenever a potential issue is detected, allowing for scheduled repairs, and preventing unnecessary losses. The software triggers maintenance actions before any damage occurs.
3. Better Visualization
Digital twin technology, integrated with software, provides 3D models for better representation of equipment or designs. This makes it easier and faster for staff to detect issues and make quick decisions.
4. Improved Teamwork
Digital twin-led mobile apps facilitate communication among team members and stakeholders. They can easily share information, reports, and other important data through the app, making communication effective and clear without the need for extensive emailing.
5. DT and AI
Digital Twins and Artificial Intelligence are impacting every industry. Experts have started employing these technologies to create sustainable equipment to reduce emissions. According to the World Economic Forum, IKEA has already improved energy efficiency and reduced greenhouse emissions in 37 of its retail stores in East Asia.
6. Self-healing Systems
Imagine machines that can diagnose and even repair themselves. With machine intelligence integrated into digital twins, these machines could proactively identify issues and take corrective actions in real time, reducing the need for human intervention.
Conclusion
The world has already embraced a digital-first approach. Engineering firms are using various technologies to save costs on equipment failures by predicting risks in a timely manner. If you own an engineering business and want to revolutionize your firm with software powered by digital twin technology, then PhoenixBizz can help.
We are a leading software development company in Arizona, proudly serving clients for over two decades. As a division of Sofvue LLC, we have established ourselves as a trusted name in the software development industry. Client satisfaction is our primary motivation, and we achieve this by leveraging the latest technologies. Our high-quality software solutions are responsive, intuitive, and tailored to meet your unique requirements.
Whether you need software, a website, or a custom mobile app, we are here to provide you with expertly designed solutions that cater to your needs.
You can call us at 623-845-2747 to schedule a call with our team.
RE: 11820
Citations:
World economic forum: https://www.weforum.org/agenda/2024/03/how-digital-twin-technology-can-work-with-ai-to-boost-buildings-emissions-reductions/
John Tomblin
Senior Software Architect - PhoenixBizz
