Submitted:
11 December 2023
Posted:
12 December 2023
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Abstract
Keywords:
1. Introduction
2. State of the Art
2.1. Digital Twin Definitions and Categories
2.2. Structural design process
2.2.1. Definition of a structure according to Wiedemann
- Wiedemann [15] defines “topology” as the number of variables and their relationship within the function. For example, the topology of a beam consists of the variance of its cross-section over its length, that of a truss of the number of its rods.
- The “shape” determines the geometric characteristics of the structural system. These are, for example, the external dimensions of a beam cross-section or the nodal coordinates of a truss.
- The “dimensioning” determines the quantitative wall thicknesses of the individual cross-section parts and thus completes the geometric description of the load-bearing system
2.2.2. Product development according to VDI guideline 2221/2019
2.2.3. Summary for structural design process
3. Analyzing the product life cycle of structures for Digital Twins
3.1. Requirements in the design phase
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Conception:
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- Clarify and specify the problem or task.
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- Determining functions
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- Searching for solution principles
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- Evaluating and selecting the solution concept
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Preliminary Design:
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- Structuring into subsystems, components and interfaces
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- Layout of components and interfaces.
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Design:
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- Integrating the entire product
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- Implementing the design and usage specifications
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- Ensuring the fulfillment of requirements by dimensioning and optimizing chosen components and interfaces
- Formalized representation of the three steps Conception, Preliminary Design, and Design
- Providing a virtual environment that represents the boundary conditions and the associated subsystem
- Interface to databases, e.g., for material comparisons, which provide additional information about properties, costs, availability, etc.
- Modeling approaches with increasing levels of detail depending on the design phase organized in hierarchical modeling
- Virtual test-bed for interaction with the (virtual) environment in an early design stage and simulation-based load case development
3.2. Requirements in the operational phase
- Providing a synchronization mechanism, in form of continues re-calibration, between real component and model
- Automated data acquisition, processing and evaluation of an SHM system of the structure
- Data merging and storage from multiple data sources including the SHM system, environmental influences, and operational data
- Provision and hierarchical coupling of suitable structural mechanical models (implicit and explicit)
- Feedback loop to enabling bi-directional coupling: For individual evaluation of the structure concerning inspections like maintenance on demand or Remaining Useful Life (RUL) [30]
3.3. Merging design and operation phase
4. Classification of Structural mechanics in Digital Twin taxonomy
4.1. Data Collection
4.2. Data Handling and Distribution
- Design and optimization of (lightweight) structures
- Monitoring of structural fatigue and damage for Predictive Maintenance Strategies
- Coupling of intervening control units to actively influence the structure utilization during operation.
4.3. Conceptional Scope
- The Digital Twin of the structure is an explicit, detailed and identical representation of a structural component.
- The Digital Twin of the structure is a sufficiently accurate implicit and partial representation of the overall system.
5. Discussion: The two archetypes of Structural Digital Twins
- A structure-designing Digital Twin for the design and concept phase.
- A structure-monitoring Digital Twin in the operational phase
6. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
| CPS | Cyber Physical Systems |
| DT | Digital Twin |
| DOF | Degree of Freedom |
| FE | Finite Element (Model) |
| HMI | Human Machine Interface |
| M2M | Machine to Machine (Interface) |
| RUL | Remaining Useful Life |
| SHM | Structural Health Monitoring |
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| Meta-Dimension | Dimension | Characteristics | ||
|---|---|---|---|---|
| Data Collection | Data Aquisition | Automated | Semi-manual | |
| Data Source | Multiple Source | Single Source | ||
| Synchronization | With | Without | ||
| Data Input | Raw Data | Preprocessed Data | ||
| Data Handling | Data Gouvern. | Rules Applied | Rules Not-Applied | |
| Data Link | Bi-Directional | One-Directional | ||
| Interface | HMI | M2M | ||
| Interoperability | None | Via Translator | Fully | |
| Purpose | Processing | Transfer | Repository | |
| Conceptual Scope | Accuracy | Identical | Partial | |
| Conceptual Elem. | Independent | Bound | ||
| Time of Creation | Digital First | Physical First | Simultaneously |
| Phase | Information Type | Data | DT Requirements |
|---|---|---|---|
| Conception | Principal Solution | ./. | Concept database |
| Conceptual load - bearing system | ./. | ||
| Material | Characteristics | Material Data-base | |
| Cost | |||
| Boundaries | Positions | Virtual environment | |
| DOF | |||
| Bearing | |||
| Installation space | |||
| Loads | Type | Virtual Test-bed for generating and testing simulation based load cases | |
| Direction | |||
| Size | |||
| Position | |||
| Preliminary Design | Subsystem | ./. | Models with low detail level (implicit) for identifying and testing influencing parameters |
| Interface | Position | ||
| DOF | |||
| Component | Length | ||
| Cross-Section | |||
| Orientations | |||
| DOF | |||
| Design | Component Shape | Dimensions | Models with high detail level (explicit) for verification |
| Dimensioning | (Wall) Thickness | ||
| Safety factors | |||
| Joints | Typ | ||
| Positions | |||
| Number | |||
| Dimensions |
| Design Phase | Operation Phase | |
|---|---|---|
| mandatory | semi-manual data acquisition | automated data acquisition |
| multiple data-sources | multiple data-sources | |
| without synchronization | with synchronization | |
| pre-processed data input | raw data input | |
| one-directional data link | bi-directional data link | |
| processing & repository purpose | processing & repository purpose | |
| partial & identical accuracy | partial accuracy | |
| digital first | physical first | |
| optional | automated data acquisition | |
| with synchronization | ||
| raw data input | pre-processed data input | |
| bi-directional data link | ||
| transfer purpose | transfer purpose | |
| identical accuracy | ||
| physical first | digital first | |
| not discussed | Data Governance | |
| Interoperability | ||
| Interface | ||
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