adopting digital twin for integrated design and ... · adop=on of technologies are being scaled and...

www.polytechnic.purdue.edu/digital-enterprise-center

ADOPTINGDIGITALTWINFORINTEGRATEDDESIGNANDMANUFACTURINGTOREDUCEPROCESSTIME

NathanW.Hartman,Ed.D.DauchFamilyProfessorofAdvancedManufacturingandDepartmentHeadDirector,DigitalEnterpriseCenterCo-Director,IndianaManufacturingCompe@@venessCenter

Jan-AndersMansson,Ph.D.Dis@nguishedProfessorofMaterials&ChemicalEngineeringDirector,ManufacturingDesignLaboratoryCo-Director,IndianaManufacturingCompe@@venessCenter


What is a digital enterprise? A digital enterprise changes the way people work and how they use information

DigitalProductDefiniHon

Cloudcompu=ng

Sensorsanddatagathering

Mobiletechnologies

Human/machineinterface

Addi=veandtradi=onalmanufacturing

Loca=ondetec=ontechnologies

Cyber-securitylayers

Customerdatacapture


Ongoing industrial challenges

Drivingproductlifecycledatawith

highfidelityrepresenta=ons

Supplychaintransforma=on

Increasingproductcomplexity

Mobility,Collabora=on,and

Interfaces

Securingdigitalproductandprocessdatathroughtheenterprise

Difficulttohirenewworkerswith

requisiteknowledge


A challenge for manufacturing…


The next industrial revolution Mechanization, mass production, automation, virtualization

hNp://saphanatutorial.com/industry-4-0/

Digitaliza=onandconnec=vity


PLM – a key element to a digital enterprise

Singularity–uniqueinforma=on

Correspondence–1:1rela=onship

Cohesion–followphysics

Traceability–capturechangesover=me

Reflec=vity–capturethestatechanges

CuedAvailability–informa=onondemand,incontext


The collaboration journey… Yesterday

Collabora=onmeantface-to-

facecommunica=on

Communica=onsoXeninserial

fashion

Youtrustedthedatabecauseyoutrustedthepersonthatgenerated

thedata


The old communications medium The paper thread


What should go into a model-based definition? Implicit and explicit information must be included

Historically,drawingscontainedbothimplicitandexplicitinforma=on.Contextwasimportantforunderstanding.However,CADtoolsrequireexplicitdefini=onofinforma=on.


Shape definition and visual clarity Many people simply use annotated CAD models as a proxy for a drawing

•  Geometrydefini=on•  Dimensionalinforma=on

•  Designintentclarity•  Explicitinforma=on


But our technology sometimes fails us…

Needs

Requirements

Func=onalAlloca=onModel

HW/SWDesignModel

AnalysisModels

ManufacturingModels

Service/MRO

PhysicalAlloca=onModel

LOTAR

•  However,s=llsequen=al

•  Dynamicmodelre-purposings=lllacking

•  MBDmustmovebeyondshape

•  Lifecycleloops=llnotconnected

Thedigitalproductdefini=onformsthecoreofhowproductinforma=onismovedthroughthissociotechnicalsystem.


And if this is to become reality… Tomorrow

DesignManufacturing

Service

Recycle

The3DdigitaldefiniHonbecomestheconduitinastandards-basedcommunica=onprocess.

Theproductmodelisthebasisforasecure,authoritaHvesourceofproductdefini=on. Youcometotrustthe

processthatgeneratesproductdata(because

thepersonmaybeunknown).


We must have a more complete communication A complete MBD supports lifecycle communication

SHAPE BEHAVIOR CONTEXT

HUMANTOHUMAN HUMANTOMACHINE

MACHINETOHUMAN MACHINETOMACHINE


How is the model structured? Singular representation vs. multiple, connected representations

Context

Shape

Behavior OR

SingularRepresenta=on Mul=pleConnectedRepresenta=ons

Shape

•  geometry•  topology•  logic•  constraints

Behavior

• materials•  process•  dim./tol.•  physics

Context

•  assembly• machining•  inuse•  re=rement

Formanypeople,itisamaNerofwhethertheyareanauthororaconsumer.MBDisfundamentaltothefutureofdigitalmanufacturing,butitismorethanaproxyforadrawing.


Our representations must match our context The evolution of representations

Documentbased

Diagrambased

AirplaneATC Pilot

Request to proceed

Authorize

Power-up

Initiate power-up

Direct taxiway

Report Status

Executed cmds

Initiate Taxi

Specifica=onsInterfacerequirements

SystemdesignAnalysis&Trade-off

Testplans

BehaviorStructureRequirements

Lifecyclebased

Drawingbased

CADbased

VirtualenvironmentbasedGeometry

Behavior

Context

MBxbased


And we must capture behavioral intentionality Physics-based modeling

•  Throughsurrogatemeta-modelscreatetoolsthatcanbeusedtoinformdecisions,inreal=me,forshopflooruse.


So we can track information flow… Seam Layer Rolls Stack Layers

Cut to Part Bounding Box Dimensions

Consolidate Layered Preform Transfer

GLOBE Pre-form Manufacturing Process

Processing Parameters:Injection Temperature,

Injection Pressure:à Mold/Press/Utilities

Fill Time,Pack & Cool Timeà Cycle Time

Processing Parameters:Pre-heat Temp à Oven Time

Press Force à Press Cost

Processing Parameters:Layer Orientations à Seaming Time

à TP Tape Usage

Material Parameters:Fiber Volume,

Polymer Volume,à Material Costs

Close / Press Cycle

Load Preform

into Mold

Demold

Transfer / Clean Mold

Packing&

Cooling

Evacuate Mold

Injection Filling

Open Mold

Inje

ctio

n M

oldi

ng P

roce

ss

Net-Shape Trimming

Preheat PreformTransfer Transfer

Intermediate Processing

FinalTrimming

Transfer to

storage

Post-processing

Transfer

Preform

Tape

SeamerLayup / Consolidation PressTape

Seamer

Finished

Part

Scrap

Scrap

Form Preform &

Injection Mold

Net Shape

Preform

Output:

48in x 48in blank

Seam Layer Rolls Stack Layers

Cut to Part

Bounding Box

Dimensions

Consolidate

Layered PreformTransfer

GLOBE Pre-form Manufacturing Process

Close /

Press

Cycle

Load

Preform

into Mold

Demol

d

Transfer /

Clean Mold

Packing

&

Cooling

Evacuat

e Mold

Injection

Filling

Open Mold

Inje

ctio

n M

old

ing

Pro

cess

Net-Shape

Trimming

Preheat

PreformTransfer Transfer

Intermediate Processing

Final

Trimming

Transfer

to

storage

Post-processing

Transfer

Processing Parameters:

Pre-heat Temp à Oven Time

Press Force à Press Cost


Layer Orientations à Seaming Time

à TP Tape Usage


Injection Temperature,

Injection Pressure:

à Mold/Press/Utilities

Fill Time,

Pack & Cool Time

à Cycle Time

DesignFlow

ManufacturingFlow


And connect our digital twin to our physical world…

0

5

10

15

20

25

$0

$10

$20

$30

$40

$50

$60

$70

$80

CycleTime(m

inutes)

CostC

ontribu=

ons($/part)

TotalLabor($/p) TotalMaterial($/p) EquipmentOpera=on($/p) Cycle=me(min)

FinishedPart

MultiLayer Consolidation PressTape Slitter

Scrap

Scrap

Form Preform & Injection Mold

Output:48in x 48in blank

Net ShapePreform


Through a connected infrastructure. PRODUCTION TRACKER COST & TIME TRACKER


The digital enterprise supply chain Leveraging supplier and process data to ensure capacity

Customer• Feedback• Closetheloop

Valida=onandTes=ng/QC• Digitalvalida=on&verifica=on• Accuracyandfidelity

FleetManagementandU=liza=on• Deliveryverifica=on• Monitoringandadjustment

Produc=onFloorIntegra=on• Intelligent,integratedequipment• Predic=vecapacity

RawMaterials• Traceability• Usage

Capabilityacrosstheenterprise

Collec=onandIntegra=onofData

Distributedsensing

DataWarehouse

SoXwareConnec=vity

Analy=csandInterfaces

UserInterfaces Intelligentmachines

DigitalProductData

Geometry Materials

Finishing

Costs Produc=onPlans

AdaptedfromKinnet,J.Crea@ngaDigitalSupplyChain:Monsanto’sJourney,October2015.


Architecture of the Digital Twin

Context

Shape

Behavior

Future

Today

MulHpleConnectedRepresentaHons

Shape

• geometry•  topology•  logic• constraints

Behavior

• materials• process• dim./tol.• physics

Context

• assembly• machining•  inuse•  re=rement

DIGITALTWINMODEL-BASEDDEFINITION

DIGITALTHREAD

MBD+ITarchitecture+Connec=vity

•  ProductLine•  Model1•  Model2•  ModelN•  Subsystem

•  Component

Temporal,lifecycle-basedlevelsofamodel-based

definiHon

InterfacesStandards

Requirements


So where do we start? Adapted from Jennifer Herron, Action Engineering

•  Strategy–  Establishenterprisestrategy–  Roadmapforslow,steadyand

accurate•  EvaluateExisHngDigitalModels

–  Drawingvs.Model-Centric–  Connectedvs.stand-alone–  Analysisvs.testresults–  Supplychaincapacity

•  BuildValueProposiHon:–  Currentstateprocessmapping–  Futurestateprocessmappingto

enablereducedcost–  Technologyevalua=ons

•  EvaluateSuppliers–  EstablishanEcosystemReadiness–  Determinegapstoimplement

technologiesanddatamodels

•  ExecuteMethodically–  Measureagainstcurrentstate–  ReportoXen

Busine

ssValue

Maturity&Capability

LOWCriteriaare

undefined,outofdate,or

both

MEDIUMCriteriaaredefined,underchange

control,andrepeatable

HIGHCriteriaare

defined,underchangecontrol,repeatable,measurable,

andcon=nuouslyimproving.

OPP

ORT

UNITY


And how do we get there? Adapted from NSC, Curtis Brown

•  DECapabilityMaturity:Technology,Tools,andStandardsarebeingassessedfortheirbusinessvalue.

•  DEReadinessMaturity:Datamodelsarebeingprovenforimplementa=oninarelevantprocessenvironment.

•  DEAdopHonMaturity:Technologiesarebeingdeployedinanopera=onalenvironment.

•  DEAdapHveMaturity:Adop=onoftechnologiesarebeingscaledandappliedtonewbutsimilarareas.

BusinessValuePUSH

PULL

CapabilityAssessment

Readinessforimplementa=on

Adop=onfordeployment

MBE

MaturityLevels

Adap=veforscalability

Tools,technology,andstandards

Processes People&organiza=ons


A shift in the focus on jobs •  Apersonborntodaycanexpectto

livetobe100-yearsold.–  Theircareerswillbe60to70

yearslongforcingthemtonotonlychangejobsbuttochangecareers.

–  Thisalignswithourcollege’stagline:“Howtopreparegraduatesforjobsthatdonotexist.”

•  ThesecondisashiXinskillrequirements.–  Demandforskillsofthehead

(cogni=ve),havedominatedthoseofthehands(technical)andtoalesserextent,thoseoftheheart(social)overthepast300years.Inthefuture,thoseskillsshiXsareabouttogointoreverse.


Parallel Revolutions

EducaHon1.0 EducaHon2.0 EducaHon3.0 EducaHon4.0

1 2 3 4 ApprenHceship Manual/Industrial

ArtsTechnologyEducaHon

Design&SystemsThinking/Makermovements

MechanizaHon ElectrificaHon AutomaHon DigitalizaHon

Regardlessoftheera,theeducaHonalrevoluHonconnectedtomanufacturinghasalwayshadafocusonthetoolsandtechniquesoftheday,toenablethedesignandproducHonofsomething.


Workforce Education for Industry 4.0

•  Builtupontheoldliteraciesofreading,wri=ngandmathema=cs.

•  Newliteraciesinclude:

–  Dataliteracy:read,analyzeandapplyinforma=on

–  Technologicalliteracy:codingandengineeringprinciples

–  Humanliteracy:humani=es,communica=onanddesign

•  Higherordermentalskills–mindsetsandwaysofthinkingabouttheworld.

–  SystemsThinking:theabilitytoviewanenterprise,machineorsubjectholis=cally,makingconnec=onsbetweendifferentfunc=onsinanintegra=veway.

–  Entrepreneurship:appliesthecrea=vemindtotheeconomicandsocialsphere.

–  CulturalAgility:howtooperatedeXlyinavariedglobalenvironment.

–  CriHcalThinking:thehabitofdisciplined,ra=onalanalysisandjudgement.


Takeaways…

•  Adopttechnologytohelpmanagecomplexity,trackcost,andenabledecisions.

•  Transformingdigitaldataauthoringandconsumingprocessesandprac=cestoachieveadigitalenterpriseisaculturechange.

•  Developcommondigitaldatamodels,andstopindividually“clerking”data

•  Dataarchitectureandcompu=nginfrastructurearekeyenablerstoadop=ngdigitalenterprisemethodsandtools.

•  Datapackaginganddeliverycanmakeorbreakadop=on.•  Ourrepresenta=onsmustmatchourcontext.•  Educa=onoftheexis@ngandfutureworkforceisimportant

forachievingtechnicalcompetenceandculturechange.


ADOPTINGDIGITALTWINFORINTEGRATEDDESIGNANDMANUFACTURINGTOREDUCEPROCESSTIME

NathanW.Hartman,Ed.D.DauchFamilyProfessorofAdvancedManufacturingandDepartmentHeadDirector,DigitalEnterpriseCenterCo-Director,IndianaManufacturingCompe@@venessCenter

Jan-AndersMansson,Ph.D.Dis@nguishedProfessorofMaterials&ChemicalEngineeringDirector,ManufacturingDesignLaboratoryCo-Director,IndianaManufacturingCompe@@venessCenter

adopting digital twin for integrated design and ... · adop=on of technologies are being scaled and...

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