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How can you optimize complex systems with digital twin software?

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Complex systems, such as manufacturing plants, supply chains, or smart cities, are often difficult to optimize due to their dynamic and interdependent nature. However, with the help of digital twin software, you can create a virtual replica of your system that can simulate, analyze, and improve its performance in real time. In this article, you will learn how digital twin software can help you optimize complex systems in industrial engineering.

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Halimah Hassan

Electronics Engineer
Santiago José Tutor Roca

R&D Project Engineer ? Digital Transformation at Navantia S.A., S.M.E. ? 1o Award for Excellence of Young Spanish…

1 What is digital twin software?

Digital twin software is a type of software that uses data from sensors, IoT devices, and other sources to create a digital model of a physical system. The digital model can mimic the behavior, state, and interactions of the real system, as well as predict its future outcomes. Digital twin software can also enable you to test different scenarios, configurations, and interventions on the digital model before implementing them on the real system.

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Halimah Hassan

Electronics Engineer
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Digital Twin software is a CAD software used to create the visual duplicate of a physical system. Data point values are output in various ways, including discrete and continuous values. You can view a pump running or not, and the bearing temperature to monitor overheating. Digital Twin software has come a long way from 2D versions like Schneider Electric's Foxboro and Rockwell Automation's FactoryTalk, though a plant floor staple. There are now 3D animations that can immulate an environment with graphics used in Hollywood CGI. Add the VR, AR, and XR capabilities using smart glasses technology and the control room, supporting documentation, and training videos can now travel with you.

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Santiago José Tutor Roca

R&D Project Engineer ? Digital Transformation at Navantia S.A., S.M.E. ? 1o Award for Excellence of Young Spanish Engineers ? Industrial PhD Student at Universidade da Coru?a
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La optimización de sistemas complejos mediante gemelos digitales implica el uso de software especializado que replica y simula de manera precisa el comportamiento de un sistema físico en tiempo real. Un gemelo digital crea una representación virtual exacta de un producto, proceso o sistema, permitiendo análisis detallados y simulaciones para mejorar su eficiencia y rendimiento. Al reflejar con precisión la realidad, los gemelos digitales posibilitan la identificación de áreas de mejora, la predicción de comportamientos y la toma de decisiones. Esta tecnología encuentra aplicaciones en diversos campos, desde la manufactura hasta la gestión de la cadena de suministro, contribuyendo a la optimización continua de sistemas complejos.

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2 Why use digital twin software for complex systems?

Complex systems are often characterized by high uncertainty, variability, and nonlinearity, which make them hard to optimize using traditional methods. Digital twin software can help you overcome these challenges by providing you with a realistic and dynamic representation of your system that can capture its complexity and adapt to changes. By using digital twin software, you can gain insights into your system's performance, identify bottlenecks, optimize resources, reduce costs, enhance quality, and increase efficiency.

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Santiago José Tutor Roca

R&D Project Engineer ? Digital Transformation at Navantia S.A., S.M.E. ? 1o Award for Excellence of Young Spanish Engineers ? Industrial PhD Student at Universidade da Coru?a
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La optimización de sistemas complejos se ha revolucionado con el uso de gemelos digitales y su software dedicado. La utilidad de un software de gemelo digital radica en su capacidad para replicar de manera precisa y dinámica sistemas físicos en entornos virtuales. Esto permite realizar análisis detallados, simular escenarios y optimizar el rendimiento sin afectar el sistema real. Al utilizar un gemelo digital, las empresas pueden prever y abordar problemas potenciales, mejorar la eficiencia operativa y acelerar el desarrollo de productos. En ese sentido, facilita la toma de decisiones informada al proporcionar datos en tiempo real sobre el comportamiento del sistema, contribuyendo así a la innovación y la excelencia operativa.

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Roi Ferreiroa Garcia

Desarrollo Software & Digitalización | Navantia S.A., S.M.E
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El uso de software de gemelos digitales ofrece una gestión de activos optimizada y una toma de decisiones basada en datos. Además, facilita la monitorización en tiempo real y el análisis predictivo, empleando algoritmos de inteligencia artificial para prever y prevenir fallos en los equipos, maximizando así la eficiencia operacional y minimizando el tiempo de inactividad. La simulación precisa y detallada que proporciona, integrada con datos obtenidos a través de dispositivos IoT, posibilita la validación y mejora de dise?os y procesos sin comprometer el equipo físico, lo que se traduce en una reducción significativa de costes operativos y de mantenimiento, además de mejorar la seguridad y sostenibilidad de las instalaciones.

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3 How to use digital twin software for complex systems?

If you want to use digital twin software for complex systems, you must first define your objectives and scope, as well as the KPIs and constraints of your system. Next, collect and integrate the data sources and formats that will feed into your digital model. Then, build and validate your digital model to reflect the structure, logic, and behavior of your real system. After that, run simulations and experiments on your digital model to explore different scenarios and outcomes. Additionally, use analytics and visualization tools to interpret and communicate your results. Finally, implement and monitor your optimization solutions from the digital model to the real system.

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Santiago José Tutor Roca

R&D Project Engineer ? Digital Transformation at Navantia S.A., S.M.E. ? 1o Award for Excellence of Young Spanish Engineers ? Industrial PhD Student at Universidade da Coru?a
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Para una correcta utilización del software, comienza creando una representación virtual precisa del sistema, incorporando datos del mundo real. Configura el gemelo digital para reflejar las condiciones y características del sistema físico. Utiliza algoritmos avanzados para simular diferentes escenarios y evaluar el rendimiento. Monitorea en tiempo real la información generada por el gemelo digital para obtener insights y tomar decisiones informadas. Itera y ajusta el modelo virtual conforme evoluciona el sistema real. Esta metodología proporciona una poderosa herramienta para la optimización continua, permitiendo a las organizaciones mejorar la eficiencia, prever problemas y avanzar en la innovación de manera ágil.

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4 What are the benefits of digital twin software for complex systems?

Digital twin software can offer many benefits for optimizing complex systems, such as saving time and money by testing solutions on a digital model before applying them to the real system. It can also improve decision making by using the digital model as a reliable source of information and guidance. Additionally, it can foster creativity and experimentation by using the digital model as a sandbox for exploring new ideas and possibilities. Finally, it can increase agility and resilience by using the digital model as a dynamic tool for adaptation and improvement.

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Halimah Hassan

Electronics Engineer
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A great benefit of using a digital twin to optimize a process is the visual simplicity it offers in deciphering large amounts of data from complex systems or networks of systems. Often a process has many systems separately collecting data. A digital twin allows colleagues who are not technically involved but high level decision makers to immediately drill down to the sensor level and view repeat issues, nuisance alarms, obsolete tech, and delegate problem solving to the correct middle-managent problem solvers. Also having a digital twin allows accountability to become inescapable and the visuals are super cool. ??

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5 What are the challenges of digital twin software for complex systems?

Digital twin software can also pose some challenges for optimizing complex systems, such as managing large volumes and variety of data while ensuring data security and privacy, as well as integrating the digital model with other systems and platforms. It is necessary to maintain and update the digital model, accounting for human factors and ethical issues that may affect it and its optimization solutions. Additionally, you need to evaluate and measure the optimization results by defining and tracking metrics and indicators that can measure the impact and value of your optimization solutions, while considering the trade-offs and side effects that may arise.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you optimize complex systems with digital twin software?

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2

3

4

5

6

1 What is digital twin software?

2 Why use digital twin software for complex systems?

3 How to use digital twin software for complex systems?

4 What are the benefits of digital twin software for complex systems?

5 What are the challenges of digital twin software for complex systems?

6 Here’s what else to consider

Industrial Engineering

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How can you optimize complex systems with digital twin software?

1

2

3

4

5

6

1 What is digital twin software?

2 Why use digital twin software for complex systems?

3 How to use digital twin software for complex systems?

4 What are the benefits of digital twin software for complex systems?

5 What are the challenges of digital twin software for complex systems?

6 Here’s what else to consider

Industrial Engineering

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