digital twin - e-university.tu-sofia.bg

Jivka OvtcharovaKarlsruhe Institute of Technology (KIT) I Karlsruhe I Germany

© Jivka Ovtcharova I 1

Seamless Engineering in the Industry 4.0 Era

DIGITAL TWIN

XXX International Scientific Conference ELECTRONICS - ET2021 I September 15, 2021 I Sozopol, Bulgaria

Jivka OvtcharovaKarlsruhe Institute of Technology (KIT) I Karlsruhe I Germany


Seamless Engineering in the Industry 4.0 Era

DIGITAL TWIN

XXX International Scientific Conference ELECTRONICS - ET2021 I September 15, 2021 I Sozopol, Bulgaria


Our competences, our visions

ABOUT US

Karlsruhe Institute of Technology

© Jivka Ovtcharova I 4Source: own representation

The Research University in the Helmholtz Association.

2009Karlsruhe Institute of Technology

1825Karlsruhe University

1956Research Center

Institute for Information Management

Knowledge Screening

(Big) Data Analytics

(Engineering)Data Acquisition

Human-MaschineInteraction

FeedbackManagement

Data Modeling and Simulation

Practical Implementation

Virtual & Experimental

Validation

Lifecycle Engineering

Virtual Environments

© Jivka Ovtcharova I 5Source: Ovtcharova 2021

Make analytics come alive with Digital Twin Ecosystem.

View of the whole, at any moment!Deep Analytics

EDUCATION RESEARCH INNOVATION

Industrie 4.0 Collaboration Lab

Opening24 September 2014

Hannover Fair14 April 2015

Award19 February 2016

Nordschwarzwald


Innovation Event Hangzhou 21 July 2017

…

„Sandbox“ for experiments in run-time environment. .Source: Industrie 4.0 Collaboration Lab (KIT)

ENSAM Institute Image 5 October 2017

Virtual Environments LabCAVE VR system

Mixed Reality LabDriving Simulation,, HTC, HoloLens,

haptic Interaction

Communication LabCo-Working-and-Sharing-Space

International Cooperation LabChina, France, Bulgaria, etc.

Value Creation LabIndustrial Case Studies and

Implementation

Experience LabDigital Twin Solutions

Content Creation LabDevelopment and Training with CAx/PLM

Tea LabCreativity-Think-Tank

Source: Ovtcharova 2018 © Jivka Ovtcharova I 7

Lifecycle Engineering Solutions Center

innovate


Why, What, How?

DIGITAL TWIN

The Beginning of Industry 4.0

Computers and automation come together in a new way.

Dream team: Prof. Kagermann, acatech Prof. Wahlster, DFKI Prof. Lukas, BMBF

at the Hannover Fair in 2011

Source: acatech © Jivka Ovtcharova I 10

Smart manufacturing in focus: System interoperability I Internet of things Information transparency I Cloud computing Technical assistance I Cognitive manufacturing Decentralized decisions I Cyber-physical systems

http://www.acatech.de/

http://www.acatech.de/uk

Causes and Consequences

End of the 18th century Beginning of the 20th century Beginning of the 70's Today

De

gre

e o

f In

no

vati

on

Time

Industrie 1.0

Mass production

Mechanizationhydro- and steam

power

Industrie 2.0

Mass distribution

Electrificationelectrical power and

vehicle mobility

Industrie 3.0

World economy

Automationcomputer and information

technology

Cyberizationsmart devices and humans, real time interconnections

Industry 4.0

Smart factory?

Industrie 4.0

Real-time economy!


5G

Real-time Economy

North America Latin America Europe Asia Africa

INTERNET-MAP 2003

North America Latin America Europe Asia

25 billion devices and 5 billion people on-line.

INTERNET-MAP 2015

Source: Gartner, Pictures: Festo / blog.kaspersky.com © Jivka Ovtcharova I 12

The World is „All-in-One“

Pictures: Chess Wise BV, LESC (KIT), Arku GmbH

Real and artificial objects co-exist in real time and in space.


MERGING OF MATERIAL AND VIRTUAL (COMPUTER GENERATED

WALK-IN) REALITIES

PERCEPTION AND COMMUNICATION IN REAL

TIME AND IN SPACE

INTUITIVE HUMAN-COMPUTER INTERACTION (LOGICAL,

COMPREHENSIBLE, INTUITIVE) IN RUNTIME ENVIRONMENT

Digital Twin: Status Quo

Mature and widespread implementation is missing.

© Jivka Ovtcharova I 14Pictures: Dassault Systèmes, IBM Watson IoT, GE

MODEL SEMANTICS IS MOSTLY GEOMETRY DRIVEN

ANALYTICS IS ALIGNED AND NOT EMBEDDED

SIMULATION AND USER INTERACTION ARE OFFLINE


Why, What, How?

DIGITAL TWIN

Definition

Digital representation of real units and processes interacting and synchronized with a certain accuracy and frequency:

• is system-of-systems,

• uses real-time and historical data,

• represents the past and present,

• simulates the future in a predictive way,

• is implemented in IT/OT systems.

Source: https://www.digitaltwinconsortium.org/glossary/ index.htm#digital-twin © Jivka Ovtcharova I 16

Core Statement

The existence of a powerful infrastructure based on open, international standards is a prerequisite to:

• support human-twin interaction,

• meet non-functional requirements such as data sovereignty, privacy, and data usage control,

• ensure interoperability and synchronization.

© Jivka Ovtcharova I 17Source: https://www.digitaltwinconsortium.org/glossary/ index.htm#digital-twin

Cybernetic model 60s

Bidirectional connectivity, at any moment!.

© Jivka Ovtcharova I 18Source: Norbert Wiener, MIT, Cybernetic model 60s, according to S. Böckl, 2005

Technical capabilities that differentiate 5G

Source: Report ITU-R M.2410-0 (11/2017) Minimum requirements related to technical performance for IMT-202 radio interface(s)

Catalyst for economic growth is connectivity enabled by 5G.


Challenges

5G leads to new frontiers of productivity and innovation.

© Jivka Ovtcharova I 20Pictures: IMI/KIT, Herrenknecht AG, LESC (IMI) Citation: adopted by Albert Einstein (1879 – 1955)

MODEL SEMANTICS IS USAGE DRIVEN AND ADAPTIVE

ANALYTICS IS INTERACTIVE AND EMBEDDED IN RUNTIME

IMPLEMENTATION GOES ALONG WITH EXPERIMENTS AND EXPERIENCES


Why, What, How?

DIGITAL TWIN

Three fundamentals

© Jivka Ovtcharova I 22Source: own presentation

Setting new norms, hands-on practices and skills.


Reference Architectural Model Industry 4.0 (RAMI 4.0)

FUNDAMENTAL #1

Overview

Image: Platform Industry 4.0

Derive rules for Industry 4.0 implementations.


Reference Architecture Model Industry 4.0 (RAMI 4.0) VDI, VDE and ZVE ensures that all participants involved in Industry 4.0 discussions understand each other.

LIFECYCLE FUNCTIONS

ARCHITECTURE

Asset Administration Shell

Source: visit, 2018

Stores all data and I4.0 interfaces about assets.


Industry 4.0 Component


Contain physical assets with their administration shells.


Communication capability of cyber-physical systems is described by real objects, which are networked with virtual objects and processes.

Digital Twin


Bi-directional connectivity of Industry 4.0 components.

Real-time-capable handling of material and service systems in different versions over the entire life cycle.

Digital Twin


Digital Twin


Bi-directional connectivity of Industry 4.0 components.

Digital Twin


Real-time-capable handling of material and service systems in different versions over the entire life cycle.

CHARACTERISTICS MEANING

Universality Generation, editing, distribution and playback

Availability Accessibility in different formats and data carriers from everywhere

Usability Multiple and multi-sided use, small space requirement

Portability Automatic processing, low transmission errors

Intelligence Quick search, evaluation, analysis and learning ability, mapping of decision and action sequences (algorithmization).


Hands-on Practice

FUNDAMENTAL #2

The „German Mittelstand“ is a Trademark

99,6 % of all companies

German thoroughness is no longer enough.

Source: BMWi/Eriksson, 10.04.2017, Pictures: Volksbank Münster © Jivka Ovtcharova I 30

58,5 % of all workplaces

81,8 % of all trainees

35,3 % of total sales

15.2%

19.6%

32.6%

6.5%

8.7%

15.2%0 - 9

10-49

50 - 249

250 - 499

500 - 999

1000 und mehr

Example: Industry 4.0 for SMEs

Company profile • 46 Participants

• 50 % deal with VR

• above-average Interest

• Industrial sectors:

– Mechanical Engineering and Plants (26%)

– Information Technology (17%)

– Civil Engineering & Architecture (12%)

– Services (12%)

– Automotive (7%)

– Electronics (7%)

– others (19%)

Number of employees

Source: Analyse der Wirtschaftlichkeit der Virtual-Reality-Technologie im Kontext von Industrie 4.0, Masterarbeit J. Dücker, KIT, 2015 © Jivka Ovtcharova I 31

Example: Industry 4.0 for SMEs

Identified hurdles• Insufficient knowledge about the topic

• Enormous time effort

• High investment risk

• Low acceptance among employees

• Low acceptance also among customers and suppliers

• No experiences in integration into business processes

• Lack of human resources and capacity

• Lack of appropriate software solutions

• Lack of practical experiences

• Missing professional skills and qualification

• Missing data preparation and analysis

• No meaningful applications

• others

Analysis of the results

© Jivka Ovtcharova I 32Source: Analyse der Wirtschaftlichkeit der Virtual-Reality-Technologie im Kontext von Industrie 4.0, Masterarbeit J. Dücker, KIT, 2015

New practice for Industry 4.0

Traditional implementation Required implementation

Source: own representation © Jivka Ovtcharova I 33

Investment

Deployment

Added value?

Deployment

Added value!

Investment

„A virtual depot - what to practice“ is necessary.

VIRTUAL DEPOT

„Sandbox“ Implementation

New skills for today's competition!

Pictures: Trumpf GmbH, Elabo GmbH, Siemens AG © Jivka Ovtcharova I 34

• Put real problems "in the sandbox“ of business units

• Think, try out, create “All-in-One“

• Apply emerging technologies playfully and quickly

• Test new solutions in runtime to gain experiences fast

• Transform knowledge into actions and skills

• Establish “Deep Digital Twin Engineering“ as a trademark


New skills

FUNDAMENTAL #3

Lifecycle Engineering


Complete data acquisition, end-to-end process simulation.

Model-based Systems Engineering

Building Information Modeling

Product Lifecycle Management

Computer-Aided Design

Cyber Physical Systems

Applications

Processes

Real-time Tooling and Execution Digital Factory

Service Engineering

Customer Feedback Management

Smart Energy

Smart City

Digital Twin

Smart Mobility

Tools

Deep Analytics


Self learning algorithms, Knowledge-based Engineering.

Fast Knowledge Extraction

Semantic Data Structuring

Various (Big) Data Collection

Machine Learning

Self Learning Analysis

Applications

Processes

Human-Machine-Interface Brain-Computer -Interface

Social Networks

e-Governance

Service Robotics

Predictive Maintenance

Condition Monitoring

IoT Platforms

Tools

Virtual Environments


Merge of virtual and physical realities.

Real-time Simulation

Real-time Rendering

3D-Scanning and -Modelling

Scene Management

Virtual Process Modeling

Applications

Processes

Virtual Reality Engine „PolyVR“ Dynamic and Scalable SW/HW

Heritage

Serious Games

Medicine

Service Prototyping

Virtual Factory

Architecture

Tools

PolyVR


Drive actions and deliver value

DIGITAL TWIN

Human-centred engineering methods

© Jivka Ovtcharova I 40Pictures left: Forschungsunion, right: IMI/KIT/bechtle AG

Real-time networking of data, assets, services and people.

BACK-ENDDATA, INFRASTRUCTURE, TECHNOLOGY

FRONT-ENDEXPERIENCE, COGNITION, KNOWLEDGE

Example IMI I KIT

Product and process simulation in real time.

© Jivka Ovtcharova I 41Videos: Industrie 4.0 Collaboration Lab (KIT)

Commissioning with Digital Twin

• RAMS (Reliability, Availability, Maintainability, Safety) live

• Validation of machines and entire production lines

• Data homogenization and quality check

• Virtual testing of machine code

• Reduction of complexity and production errors

• Adaptation and reduction of interfaces

• Increasing transparency for end customers

• Increasing visibility and competitiveness

Do it right the first time!

© Jivka Ovtcharova I 42Pictures: Industry 4.0 Collaboration Lab (IMI/KIT)

• Holistic training during and after development

• Early generation of technical documentation

• Shortening the time to real use

• Improving user-friendliness for different groups:

Developers, Engineers, Operators, Administrators,

Suppliers, Managers

• Optimization of condition monitoring and

predictive maintenance scenarios

Qualifying with Digital Twin

Learn it right the first time!

Pictures: Industry 4.0 Collaboration Lab (IMI/KIT), Video: IMI/KIT with Siemens AG – Power Generation Services Division / Siemens Power Academy, Karlsruhe © Jivka Ovtcharova I 43

• For required 20 year service life

Installation costs = repair costs (1 Mio. €/MW)

• The operation costs: dramatically high

Crane 10.000 € / day, ship off-shore 100.000 € / day

• Damage costs due to failure: immense

• Simulation instead of putting „hands-on“

Transfer measurement data and simulate real processes

Monitoring with Digital Twin

Act in real-time!

Pictures: Industry 4.0 Collaboration Lab (KIT) © Jivka Ovtcharova I 44

Information Management in Engineering at KIT


Jivka OvtcharovaInstitut für Informationsmanagement im Ingenieurwesen, Karlsruher Institut für

Technologie

The Future is now

First Choice Partner!

digital twin - e-university.tu-sofia.bg

Documents