What is a digital twin?

A digital twin is a model that digitizes information in the real world and reproduces it in a virtual space to correspond to the real world.

In recent years, with the development of technologies such as IoT, AI, and VR, it has become possible to build highly accurate digital twins and use them for analysis. In this article, we will explain the benefits and technology of digital twins, as well as how to use them in Japan and overseas.

What is a digital twin

A digital twin is a model that corresponds to the real world by digitizing the information of the real world (physical space) and reproducing it in the virtual space (digital space) .

In a narrow sense, it refers to a dynamic model that has real-time information linkage between physical space and digital space, and enables analysis and future prediction. In a broader sense, information captured in digital space (3D models, etc.) may also be called a digital twin.

By using digital twin information to simulate and analyze future changes, you will be able to reduce costs, improve operational efficiency, and prepare for failures.

Reasons why digital twins are attracting attention

Creating a digital twin requires various pieces of information about the physical space. In the past, information about physical space was acquired through a lot of manual work.

In recent years, with the development of technologies such as IoT, AI, and VR , it is becoming possible to construct and analyze highly accurate digital spaces in real time . With the development of such technology, digital twins are attracting attention as a feasible technology.

Digital twins have the potential to drive innovation in industry, so they are expected to be used in many fields, including the manufacturing and energy industries.

Benefits of using a digital twin

What are the benefits of building and leveraging a digital twin? In particular, we will introduce the advantages in the manufacturing industry.

Efficient development and manufacturing

Developing a new product costs a lot of money. For example, in the planning and design process of the manufacturing and construction industries, prototypes are created many times based on blueprints and tested. Depending on the test results, we had to recreate the design from scratch.

Using a digital twin to examine a 3D model in a virtual space allows for more prototyping and testing than in a physical space, making it possible to discover product defects that could not be found using conventional methods. Since the number of prototypes in physical space can also be reduced, development costs can be reduced and manufacturing lead times can be shortened.

Operation efficiency

With conventional equipment, when trouble occurred during operation, the cause was analyzed and countermeasures were taken afterward. Even in such situations, countermeasures can be taken in advance by creating a digital twin.

By sending sensor information to the digital twin at any time or at regular intervals, it is possible to detect anomalies such as failures and their symptoms on the digital twin and prevent the operation from stopping. It also reduces the number of scheduled maintenances, as maintenance only needs to be done when needed .

Enhanced after-sales service

Using the information in the digital twin, even after the product is shipped, it will be possible to know the status of parts and batteries due to the use of the product by the customer .

By providing after-sales service at the right time , users will be able to respond quickly to their problems, which will lead to higher customer satisfaction.

Technologies that compose digital twins

To configure a digital twin, we need sensors that detect the state of the physical space, a network that transmits that information, an information infrastructure that stores, processes, and analyzes data, and a means of visualizing the analysis results. Let’s see what kind of technology each has.

IoT

IoT (Internet of Things) refers to the transmission and reception of information via the Internet by things such as sensors and surveillance cameras. Collecting data regularly from all locations using IoT is the first step to creating a highly accurate digital twin.

When using data collected by IoT across organizations and countries, standardization of information on digital twins becomes important so that information can be provided immediately.

High-speed, large-capacity, low-delay communication technology is required to collect data acquired by IoT in a data center such as the cloud.

One of the means for that is 5G (5th generation mobile communication system). 5G is a mobile communication technology aimed at improving network speed and reliability. 5G is a promising technology for building real-time digital twins.

AI (Artificial Intelligence) means “artificial intelligence” in Japanese.

The vast amount of data collected by IoT is processed for ease of use and used for analysis and prediction. AI is capable of accurately analyzing and predicting this enormous amount of data. By using AI, it becomes possible to process huge amounts of data, discover anomalies and new patterns, and predict future situations from the collected data.

AR/VR

Visualizing the analysis and prediction results performed by AI and showing them to people in an easy-to-understand manner is also an essential technology for digital twins. In particular, expectations are high for AR and VR technologies that enable virtual space simulation.

AR (augmented reality) is a technology that overlays digital content on the real world. VR (virtual reality) refers to technology that allows you to experience virtual space as if it were the real world.

Both of these technologies are still in the development stage, but as communication advances and computer processing power improves, they will play a role in visualization technology for digital twins.

Examples of digital twin utilization in Japan

Here are three examples of digital twin utilization in Japan.

Komatsu: Converting the entire construction site to DX

Komatsu, a general machinery manufacturer, has achieved digital transformation (DX) for the entire construction process at construction sites.

Komatsu has digitized each process of construction, such as survey/measurement, construction planning, construction/construction management, and inspection (vertical digitization). Investigation and surveying are 3D surveys using drones, and construction planning is 3D construction planning and simulation.

As a next step, we aimed to connect each digitized process (horizontal digitization). As a result, data from the previous process can be quickly delivered to the next process through the digital twin.

Furthermore, information connecting multiple sites is also digitized (back digitization), and construction is optimized while synchronizing the actual site and the digital site (digital twin).

Kajima Corporation: Obic Midosuji Building

Kajima Corporation, a major general construction company, has digitized all information from the planning and design phases, the construction phases, and the maintenance and management and operation phases of the new construction of the Obic Midosuji Building in Chuo-ku, Osaka, to create a digital twin. did.

Kajima Corporation uses BIM models as a specific method for digital twins. This is a mechanism that reproduces a three-dimensional model of the same building as the real one on a computer called a BIM model, and utilizes it to create better buildings.

Digital twin implementation using BIM models is carried out in the planning/design phase, construction phase, and maintenance/management/operation phase.

In the maintenance and management/operation phase, information obtained from inspections is accumulated on the platform, and the knowledge obtained is fed back to the planning/development phase to circulate digital data and improve efficiency and quality. is.

Mitsui Ocean Development

MODEC has developed FPSO (Floating Offshore Oil and Gas Production, Storage and Offloading) and FSO (Floating Offshore Oil and Gas) facilities for producing oil and gas offshore Brazil. We have succeeded in reducing downtime by approximately 65% ​​by using digital twin technology for storage and loading equipment.

Sea water contains deposits (scale) of marine organisms such as magnesium, calcium and barnacles. Once solidified, it is difficult to remove and may cause malfunctions such as clogging of pipes.

Therefore, we developed a digital tool to identify events at an early stage by utilizing the data acquired from more than 10,000 sensors installed in each FPSO/FSO. We identify anomalies from prediction models based on digital twins and connect them to failure prediction.

Overseas case

What are some examples of the use of digital twins overseas? I would like to introduce three of them.

China: Shanghai INESA

At INESA, a color filter manufacturer in Shanghai, China, all factories, facilities, and equipment are converted into data and reproduced as a digital twin.

INESA uses the “Intelligent Dashboard” function of the manufacturing digital place “COLMINA” provided by Fujitsu, a partner, to visualize the data of the digital twin factory and perform work.

By using these functions, even if an abnormality occurs in the equipment in the factory, it will be possible to quickly deal with it and consider improvements. Even if the person in charge of equipment maintenance is in a remote location, they can give instructions while viewing real-time information on the digital twin.

Germany: Siemens

German electronics and digital technology company Siemens cites a “Comprehensive Digital Twin” as one of its strategies for building a system that connects data to effective decision-making.

Digital twins are essential to manufacturing, connecting information about design, planning, manufacturing and product performance.

Let’s take a look at how we are simulating, predicting and optimizing products and production systems to reduce development time.

In the production of bicycle helmets, the customer’s head is photographed at the sales store, the data is sent to the manufacturer, and the manufacturer uses simulations to design the helmet. At the factory, simulations are performed on the digital twin, and helmets are produced using equipment that uses 3D printing technology.

By producing products directly from design data in this way, it is possible to shorten the lead time to market.

Singapore: Virtual Singapore

Singapore boasts one of the highest population densities in the world, is undergoing rapid urban development, and faces challenges such as traffic congestion and construction noise.

Therefore, in order to solve the problem in cooperation with government agencies and ministries, the “Virtual Singapore Project” was carried out to convert everything that exists in the country, such as parks, roads, and buildings, into 3D data and reproduce it as a digital twin in virtual space. It is

By utilizing 3D models, it is possible to determine the bus schedule with the most efficient transportation, and to proceed with water pipe construction work undertaken by different organizations in an optimal manner at the same time.

Such efforts not only reduce wasted time and costs, but also reduce noise caused by construction work.

Summary: Development of management strategies and information infrastructure based on the premise of digital twins

We introduced the benefits and technology of digital twins, their importance in DX, and examples of their use.

Digital twins are mainly used in the manufacturing industry to reduce costs and improve operational efficiency . In Japan, the Digital Agency’s “Data Strategy Task Force 1st Summary” states that as a vision of data strategy, it aims to create a human-centered society that balances economic development and the resolution of social issues, based on the premise of digital twins. .

Each company needs to prepare for data linkage across organizations and national borders by developing management strategies that utilize digital technology and improving information infrastructure .

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