VTU plans and delivers state-of-the-art process plants. The range of services extends from plant optimization to the overall planning of large projects. In the context of digitization throughout the planning process, there is an increasing focus on the use of digital twins. An example is presented here.

In a specific project, VTU served as the EPCMv general planner (Engineering, Procurement, Construction Management, Validation) from concept design to the start-up of a new plant. In line with Integrated Engineering, which VTU has been implementing for several years, all digital plans generated during the process planning were available in a Common Data Environment (CDE). From these data, a functional digital twin of the process could be created within 3 weeks. Thus, the newly planned process could be digitally represented as a mathematical model months before the physical process existed. This digital twin could be precisely controlled through the process control system, just like the real process. Therefore, interaction with the digital twin was possible even before the plant was operational.

Reduced development and commissioning times

What benefits did the digital plant twin bring? Overall, the total development time of the project was reduced by 10%. Thanks to the early availability of the digital twin, various tasks were advanced, such as operator training, virtual commissioning of the software, and initial software tests based on simulations. Long lead times for hardware components could be optimally utilized, resulting in a 30% reduction in commissioning time.

In the specific project, 25% of all operator training was conducted using the digital twin. As the workflow could be defined early on, changes to the process were easy to accommodate. On the other hand, the digital plant twin also allowed for tests and changes without physical influences, thereby eliminating any risk to plant safety.

Stefan Pauli, Mario Petschenig: So steigen Sie schneller in die Produktion ein. in: Digital Engineering Magazin (2023), 07/2023 S. 32-33.

Rolls-Royce, a global leader in aerospace propulsion systems, has embraced digital twins to revolutionize the design, operation, and maintenance of its aero engines. Digital twins, virtual replicas of physical assets, provide Rolls-Royce engineers with a comprehensive understanding of engine behavior and performance, enabling them to optimize performance, enhance efficiency, and extend engine lifespan.

Digital twins serve as virtual replicas of Rolls-Royce engines, incorporating real-time data from sensors embedded within the engines. This continuous data stream allows Rolls-Royce to monitor the engine's health and performance, enabling proactive maintenance and preventing potential failures. By analyzing historical data and simulating future scenarios, Rolls-Royce can optimize engine operation, extending its lifespan and reducing operational costs.

Intelligent Engines: A Symphony of Technology

Rolls-Royce's Intelligent Engine concept goes beyond mere monitoring; it integrates advanced technologies to enhance engine performance and sustainability. Artificial intelligence (AI) algorithms analyze sensor data, identifying patterns and predicting potential issues before they arise. This predictive maintenance approach minimizes unplanned downtime and ensures aircraft availability.

Real-Time Data for Enhanced Performance

Real-time data from sensors also feeds into adaptive control systems, allowing the engine to adjust its operation in real-time, optimizing performance and fuel efficiency under varying conditions. This dynamic optimization ensures that the engine always operates at its peak, reducing fuel consumption and emissions.

A Holistic Approach to Aviation Excellence

The combination of digital twins and intelligent engines represents a holistic approach to aviation excellence. Rolls-Royce leverages these technologies to deliver a range of benefits, including:

• Predictive maintenance: Preventing failures and reducing downtime.

• Performance optimization: Enhancing fuel efficiency and reducing emissions.

• Improved reliability: Ensuring aircraft availability and operational safety.

• Personalized maintenance: Tailoring maintenance schedules to individual engine usage.

Rolls-Royce: Shaping the Future of Aviation

Rolls-Royce's commitment to digitalization and innovation is shaping the future of aviation. By harnessing the power of digital twins and intelligent engines, the company is delivering cutting-edge propulsion solutions that are more efficient, sustainable, and reliable. As the aviation industry continues to evolve, Rolls-Royce is poised to remain at the forefront, driven by its commitment to technological advancement.

<p>- <a href="https://www.rolls-royce.com/media/our-stories/discover/2019/how-digital-twin-technology-can-enhance-aviation.aspx" target="_blank">https://www.rolls-royce.com/media/our-stories/discover/2019/how-digital-twin-technology-can-enhance-aviation.aspx</a></p><p>- <a href="https://www.aerospacemanufacturinganddesign.com/article/the-intelligentengine/" target="_blank">https://www.aerospacemanufacturinganddesign.com/article/the-intelligentengine/</a></p><p>- <a href="https://diginomica.com/how-rolls-royce-improving-engine-sustainability-real-time-data-and-digital-twins" target="_blank">https://diginomica.com/how-rolls-royce-improving-engine-sustainability-real-time-data-and-digital-twins</a></p><p>- <a href="https://www.cio.com/article/188765/rolls-royce-turns-to-digital-twins-to-improve-jet-engine-efficiency.html" target="_blank">https://www.cio.com/article/188765/rolls-royce-turns-to-digital-twins-to-improve-jet-engine-efficiency.html</a></p>

The automotive industry is undergoing a rapid transformation, driven by advancements in technology and the ever-increasing demand for sustainable and efficient production processes. BMW, a leading global automotive manufacturer, is at the forefront of this transformation, embracing digitalization to enhance its manufacturing capabilities and achieve operational excellence. At the heart of BMW's digitalization strategy lies the concept of the digital twin, a virtual representation of its physical production processes.

iFactory Digital: The Virtual Factory

A key aspect of BMW's digital twin strategy is the iFactory Digital initiative, which aims to create a virtual factory that mirrors the physical production environment. This virtual factory will enable BMW to design, test, and optimize new production processes before they are implemented in the real world, reducing the risk of errors and ensuring a smooth and efficient transition.

BMW's Partnership with NVIDIA

To realize the full potential of the digital twin, BMW has partnered with NVIDIA, a leading provider of artificial intelligence (AI) and computing technologies. NVIDIA's Omniverse platform, a cloud-based platform for building and operating physically accurate simulations, provides the foundation for BMW's digital twin initiative.

Testing and Optimization with the Digital Twin

BMW is already leveraging its digital twin to test and optimize its production processes. For instance, the company is using the digital twin to simulate the impact of new production methods on efficiency and productivity. This allows BMW to make informed decisions about process improvements without disrupting actual production.

Enhancing Employee Training

The digital twin also plays a crucial role in employee training. BMW is using virtual reality (VR) headsets to immerse employees in the virtual factory, allowing them to experience and learn about new production processes in a safe and interactive environment. This immersive training method enhances employee understanding and reduces the time required for onboarding new personnel.

Driving Sustainability

BMW's digital twin initiative also contributes to the company's sustainability goals. By optimizing production processes, reducing downtime, and minimizing material waste, BMW is able to lower its environmental impact and contribute to a more sustainable future for the automotive industry.

Conclusion: A Paradigm Shift in Manufacturing

BMW's embrace of the digital twin represents a paradigm shift in automotive manufacturing. By harnessing the power of digital simulation and AI, BMW is transforming its production processes, enhancing efficiency, reducing environmental impact, and setting new standards for the industry. The digital twin is not just a tool; it is a strategic asset that will drive BMW's success in the years to come.

<p>- <a href="https://blogs.nvidia.com/blog/bmw-group-nvidia-omniverse/" target="_blank">https://blogs.nvidia.com/blog/bmw-group-nvidia-omniverse/</a><a href="https://blogs.nvidia.com/blog/bmw-group-nvidia-omniverse/" target="_blank"></a></p><p>- <a href="https://www.bmwgroup.com/en/news/general/2022/bmw-ifactory-digital.html" target="_blank">https://www.bmwgroup.com/en/news/general/2022/bmw-ifactory-digital.html</a><a href="https://www.bmwgroup.com/en/news/general/2022/bmw-ifactory-digital.html" target="_blank"></a></p><p>- <a href="https://www.automotiveit.eu/technology/nvidia-bringt-bmw-ins-omniverse-92-414.html" target="_blank">https://www.automotiveit.eu/technology/nvidia-bringt-bmw-ins-omniverse-92-414.html</a><a href="https://www.automotiveit.eu/technology/nvidia-bringt-bmw-ins-omniverse-92-414.html" target="_blank"></a></p><p>- <a href="https://www.cio.de/a/bmw-erprobt-produktion-mit-virtuellem-modell,3709657" target="_blank">https://www.cio.de/a/bmw-erprobt-produktion-mit-virtuellem-modell,3709657</a></p>