Validation of Product Requirements - Specifications Using Field Data and Next Generation Vehicle Design Strategy Using a Calibrated Digital Twin

The engineering design process employs an iterative approach in which proposed solutions are conceived, evaluated and refined until they satisfy a priori requirements - specifications. This iterative cycle generally uses computer aided designs (CAD), engineering analysis (CAE), numerical simulations per operating scenarios, and laboratory or field prototype testing. The availability of product data can be applied to assess the vehicle requirements – specifications to facilitate the next generation design. However, the calibration and use of a digital twin facilitates exploration of tradeoffs between engineering design, product manufacturing, and business demands, plus a desire to shorten the overall time. For instance, digital twin technology enables the swift evaluation of vehicle performance in various configurations and operating conditions. The question arises of how to best integrate digital twin technology into the design process. This paper will review the engineering design process, use of field data for product evaluation and calibration, and how digital twin technology can advance the next generation of transportation products. A case study will focus on an off-road track vehicle with accompanying specifications-requirements and closed-course operating data to evaluate the design and prescribe general updates in the next-generation product. The data-based assessment methodology revealed that most specification and requirements were satisfied while the unsatisfactory ones were highlighted for further review in subsequent design cycles using the calibrated digital twin toolset. Overall, the emergence of virtual engineering design methods can positively impact the design process and lead to more competitive products within the global marketplace.