Using Digital Twins with Immersive 3D Visualization in the Inspection Industry

This article excerpt was originally published in the NDE Outlook column in the July 2024 issue of Materials Evaluation . NDE Outlook focuses on possibility thinking for NDT and NDE. Topics may include technology trends, research in progress, or calls to action. To contribute, don't hesitate to get in touch with Associate Technical Editor Ripi Singh at [email protected] . Read the full piece here .

Author: Ali Merchant, PhD: Founder and CEO, iQ3 Connect, Woburn, MA [email protected]

Background

The inspection industry plays a crucial role across various sectors, including manufacturing, construction, oil and gas, and infrastructure. Inspections ensure compliance with safety standards, quality control, and maintenance schedules, mitigating risks and enhancing operational efficiency. Traditionally, inspections rely on manual processes and physical presence, which can be time-consuming, costly, and often hazardous. Advancements in reality capture and digital twins are creating a solid foundation for true-to-scale (1:1) immersive 3D visualization in virtual reality (VR), augmented reality (AR), and mixed reality (MR). This combination offers innovative solutions for virtualizing inspector training, enabling real-time collaboration, and visualizing data analysis. These advancements have the potential to revolutionize traditional inspection methods.

Creating and Visualizing Persistent Digital Twins

Inspections generate vast amounts of data, including measurements, photos, and notes. Drones capture detailed lidar data, which can serve as a precise 3D foundation for creating digital twins. Additionally, many industries possess design or CAD drawings that, when combined with lidar or scan data, can enhance detail and accuracy. Data capture can also include 360° images and videos, which can further enrich the digital twin. Adding documentation and real-time sensor data to the digital twin provides live, actionable information. A digital twin, visualized at a 1:1 scale on immersive reality devices, creates opportunities to virtualize inspection processes that traditionally rely on in-person activities. These digital twins can be accessible 24/7 in a persistent manner for a variety of business applications. Open web-based rendering technologies, such as WebGL and the more advanced WebGPU, offer powerful and scalable solutions for diverse business needs. Additionally, the recent WebXR and OpenXR standards provide a unified, vendor-agnostic approach to supporting VR, AR, and MR devices, reducing key obstacles to business adoption. An example of using web technologies for extended reality (XR), which includes VR, AR, and MR, can be viewed live at https://iq3connect.com .

Opportunities

Enhanced Safety, Efficiency, and Reduced Disruptions

A digital twin environment can significantly enhance safety by reducing the need for physical presence in hazardous areas. It also lowers the costs involved with travel and moving equipment, resulting in increased operational efficiencies and fewer business disruptions. Inspectors can perform virtual walkthroughs to examine dangerous or hard-to-reach areas at their own pace, reducing the risk of accidents. Incorporating immersive VR and AR into inspection processes allows for accurate 1:1 scale visualization, which flat-screen methods cannot achieve. This new approach reduces the necessity of being on-site, further decreasing business disruptions when travel is impractical.

Inspector Training

Digital twins with immersive training environments can simulate real-world inspection scenarios. VR can create realistic 3D environments where trainees can practice inspections without the limitations of physical locations. For instance, a trainee can virtually inspect an oil rig, practicing safety protocols and identifying defects in a controlled setting. AR and MR can enhance on-the-job training by overlaying digital information on physical objects. Inspectors can use AR glasses to receive step-by-step guidance, access technical documents, and visualize internal structures. This reduces the learning curve and improves accuracy.

Real-Time Collaboration with Experts

Similarly, a multiuser environment with digital twins can enable real-time collaboration between on-site inspectors, remote experts, and stakeholders in various locations. An inspector in the field can use AR glasses to share their viewpoint with an expert elsewhere, who can then provide immediate feedback and guidance. This capability is especially valuable in complex or hazardous environments where expert input is critical. Collaborative platforms can enhance this further by allowing remote experts to annotate the inspector’s field of view, highlight areas of concern, and suggest corrective actions.

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