Let’s Build Better, Stronger, Faster Machines with Intelligent Performance Engineering

The popular 1970s sci-fi show The Six Million Dollar Man follows the adventures of USAF Colonel Steve Austin, who is rebuilt with bionic implants following an accident. Its iconic opening narration speaks to the transformative power of technology: “Gentlemen, we can rebuild him. Better than he was before. Better… stronger... faster."

While we may be far from a bionic man, the field of machine engineering is enabling better, stronger and faster development every day through intelligent performance engineering (IPE). As a comprehensive digital thread, IPE includes elements such as digital twin software, as well as artificial intelligence (AI) and augmented reality (AR) that help manufacturers collaborate more effectively. IPE significantly improves design, simulation and validation processes throughout the manufacturing cycle, and allows for more efficient evaluation of the capabilities and limitations of different product variations.

Let’s look at how these innovations help design teams overcome some of the industry’s most persistent challenges to work more collaboratively, seamlessly and profitably.

Competition and Demand is an Uphill Battle for Manufacturers

Manufacturers face considerable challenges in the modern economic landscape, which highlights the urgent need for IPE. With a majority of machines now being custom-made to order, engineers face pressure to meet increasing customer demand for personalization without compromising cycle rates or delivery schedules.

?Siloing can also create coordination and collaboration challenges impacting the overall usability of a product, as a single machine is often used in multiple environments. Without safe, reliable and cost-effective solutions, running design, simulation and validation in unison becomes a pie-in-the-sky dream for many machine shops. Likewise, original equipment manufacturers (OEMs) continually struggle to improve equipment reliability and machine performance while simultaneously delivering products to market as fast and efficiently as possible. When extensive testing and validation procedures are conducted late in the development lifecycle, there can be production delays and additional financial costs.

?As global competition continues to pose its own challenges, manufacturers will need to differentiate their products, continually innovate and serve customers faster and at a lower cost. If we can learn anything from Steve Austin’s antagonist Jeffrey Dolenz, who built inferior robots to combat the show’s more technologically-advanced hero, it’s that manufacturers need to adopt the most cutting-edge solutions to keep rivals at bay.

Digital Twins Come to the Machine Builder’s Rescue?

IPE can address today’s manufacturing hurdles through “digital twin” software, which effectively counters siloing by bringing different specialties into a collaborative virtual space. By fostering an environment for design, simulation and validation happen simultaneously, they reduce time to market and development costs, and allow engineers to easily optimize and troubleshoot machines with the following processes:

a.??Multi-physics machine simulation — Simulation provides visibility on different complexities, addressing varying production needs while simultaneously enabling the study of different physics across domains.

b.??Integrated machine design and simulation — Integrated design creates a primary model concept of the same models across tools. This keeps simulation data in sync with design and allows libraries of components built over decades to easily be used to simulate various what-if scenarios in the early design phase.?

c.??Closed-loop validation — Whether it be scrap, noise or vibration, closed-loop validation leverages the IoT to validate simulations virtually through field data to correlate real-time feedback into the simulation environment. It increases simulation accuracy and assists manufacturers with addressing potential issues before they emerge.

Digital twins go a long way toward increasing machine shop innovation and their customers’ increasing desire for customization. Now, manufacturers can deploy 1D and 3D modeling to simulate design trade-offs for their clients and more easily incorporate their specifications.

AI and AR Technology Enable Advanced Manufacturing

Closely connected to the digital twin is artificial intelligence (AI) and augmented reality (AR), which are integral to compiling the real-time information necessary for optimal designs. Machines need to perform well under constantly changing conditions, and AI can monitor performance and convey data necessary for engineers to perform necessary adjustments. It also safeguards the reliability of manufacturing equipment through predictive maintenance. Neural networks and custom models can be overlaid on the production process, detecting abnormal situations without user intervention and allowing operators to immediately respond. This can dramatically shrink non-conformance costs and tool breakdown expenditures.

The use of AR is also increasing, allowing machines produced in one country to be quickly deployed across the globe. AR systems allow engineers to get real-time data to do maintenance and repair and ultimately resolve customer problems from anywhere at any time. AR has a role in accelerating skills development as well, which improves worker productivity and creates new business value.

Final Thoughts and Next Steps

While we don’t yet have widespread cyborgs as charming and funny as Steve Austin, IPE technologies can propel more manufacturers into the future, enabling them to go to market faster, spend less and keep up with the rising tide of global competition. With AI, AR and the digital twin, smart manufacturing can become increasingly widespread. We have the technology to build our machines better, stronger, faster than before; now let’s use it!?

?Learn how to spur innovation and go to market faster through intelligent performance engineering!