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How to Quickly Create a Simulation-Based Digital Twin of an IIoT-Connected Product

Digital twins are virtual representations of physical products. They have the ability to unlock value and optimization throughout a product’s lifecycle. By leveraging real-world data from IIoT-connected product and physics-based simulations, digital twins can better inform and predict product performance. This enables users to develop new designs, operations and controls to optimize performance, reduce downtime and enable service-based products — often without the customer needing to upgrade hardware. The technology to get an IIoT digital twin running is available, however, many organizations are having a hard time implementing and connecting all of the digital, physical and data assets together. With the help of ANSYS Twin Builder and PTC ThingWorx, engineers can simplify the creation of digital twins using physics-based simulations.

In this example, a digital twin of an electric motor will be made using ANSYS Twin Builder and PTC ThingWorx.

The physical motor asset has a voltage and a current sensor. Its loads are then controlled using solenoids.

Creating a digital twin of this asset doesn’t require any sensors within the motor or on its rotor to determine its temperatures. To predict the motor’s temperature, engineers have to first develop a physical representation of the motor in ANSYS Multiphysics software.

Once the modeling is completed, it is integrated into Twin Builder using a reduced order model (ROM) and used to create a digital twin of the motor.

ANSYS Twin Builder workflow for developing and deploying digital twinsANSYS Twin Builder workflow for developing and deploying digital twins
This digital twin can predict the motor’s current and future maximum temperature, in real time, based on the current. The digital twin can be exported and deployed on an IIoT platform, in this case PTC ThingWorx, to predict the remaining useful life of the motor for predictive maintenance purposes.

To learn how to build an IIoT digital twin in more details, watch the webinar: Product Simulation Models Incorporated into Digital Twin Applications to Accelerate Monitoring and Service.

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