Browse Topic: Digital twin

Items (169)
Off Highway vehicles recreation has rapidly expanded across the globe hence it is important to consider the safety of off-highway vehicles which is significantly influenced by various environmental factors, which can pose unique challenges and risks. it is important to make sure that the entire vehicle operates safely and reliably even in the toughest conditions. This paper investigates the impact of environmental conditions on the safety and performance of off-highway vehicles, such as construction equipment, agricultural machinery, and mining vehicles. By examining factors such as terrain, weather conditions, visibility, and natural obstacles, the study aims to identify key hazards and propose strategies to mitigate them. The paper explores how advanced technologies, including digital twins and predictive analytics, can be leveraged to enhance safety measures and improve vehicle resilience in diverse environmental settings. Through comprehensive case studies and empirical data, we
Mogal, MasthanvaliChennamalla, Chandra Shekar
The evolution of Autonomous off-highway vehicles (OHVs) has transformed mining, construction, and agriculture industries by significantly improving efficiency and safety. These vehicles operate in high dust, uneven terrain, and potential communication failures, where safety is challenged. To guarantee vehicle safety in such situations, a robust architecture that combines AI-driven perception, fail-safe mechanisms, and conformance to many ISO standards is required. In unstructured environments, AI-driven perception, decision-making, and fail-safe mechanisms are not fully addressed by traditional safety standards like ISO26262 (road vehicles), ISO19014 (earth-moving machinery and it is replacing withdrawn ISO 15998), ISO12100 (Safety of machinery) and ISO25119 (agriculture), ISO 18497 (safety of highly automated agricultural machinery), and ISO/CD 24882 (cybersecurity for machinery).These standards mainly concentrate on the reliability of mechanical and electric/electronic systems
Muthusamy, Sugantha
Warranty claims function as primary source of characterizing field failures across industries, wherein appropriate classification of these claims is critical for further analysis. The classification of warranty claims is a highly laborious effort, involving significant man-hours of warranty analysts. This can be highly optimized and made efficient using direct interpretation of the claim data on 3D model using unity game engine. Additionally, the color perception technique using immersive technology (AR/VR) can help to identify the vital few & drive prioritization of the field failures leading to faster problem resolution. The capabilities of UI/UX & advanced visualization are integrated to develop novel methods to classify the warranty claims & interpret it on a 3D model using immersive technology which is novel and one of its kind in industry. Unique characteristics of this tool is it focuses on the warranty claim classification by claim cost & count of claims and presents the heat
Nankery, Viveksavadatti, SandeepShete, AtulApkare, SanketGanapathi, Poongundran
Modern battery management systems, as part of Battery Digital Twin, include cloud-based predictive analytics algorithms. These algorithms predicts critical parameters like Thermal runaway events, state of health (SOH), state of charge (SOC), remaining useful life (RUL), etc. However, relying only on cloud-based computations adds significant latency to time-sensitive procedures such as thermal runaway monitoring. This is a very critical and safety function and delay is not acceptable, but automobiles operate in various areas throughout the intended path of travel, internet connectivity varies, resulting in a delay in data delivery to the cloud and similarly delay in return of the detected warning to the driver back in the vehicle. As a result, the inherent lag in data transfer between the cloud and vehicles challenges the present deployment of cloud-based real-time monitoring solutions. This study proposes application of Federated Learning and applying to a thermal runaway model in low
Sarkar, Prasanta
Hydrogen Internal Combustion Engines (H2 ICEs) are seen as a viable zero-emission technology that can be implemented relatively quickly and cost-effectively by automotive manufacturers. The changed boundary conditions of a hydrogen-fueled engine in terms of mechanical and thermal aspects require a review and potential refinement of the design especially for the 'piston bore interface' (liner honing, ring and piston design) but also for other engine sub-systems, e.g. the crankcase ventilation system. The influence of oil entry into the combustion chamber is even more important in hydrogen engines due to the risk of oil-induced pre-ignition. Therefore, investigations of the interaction between friction, blowby and oil transfer into the combustion chamber were performed and are presented in this paper. During the investigations, experimental tests were carried out on a single-cylinder engine ('floating liner') and on a multi-cylinder engine. The 'floating liner' concept allows the crank
Plettenberg, MirkoGell, JohannesGrabner, PeterGschiel, KevinHick, Hannes
Reliable antenna performance is crucial for aircraft communication, navigation, and radar detection systems. However, an aircraft's structure can detune the antenna input impedance and obstruct radiation, creating a range of potential problems from a low-quality experience for passengers who increasingly expect connectivity while in the air, to violating legal requirements around strict compliance standards. Determining appropriate antenna placement during the design phase can reduce risk of costly problems arising during physical testing stages. Engineers traditionally use a variety of CAD and electromagnetic simulation tools to design and analyze antennas. The use of multiple software tools, combined with globally distributed aircraft development teams, can result in challenges related to sharing models, transferring data, and maintaining the associativity of design and simulation results. To address these challenges, aircraft OEMs and suppliers are implementing unified modeling and
Despite growing investments, the widespread adoption and scalable deployment of generative artificial intelligence (AI) remains a challenge due to data trustworthiness, regulatory uncertainty, interpretability, and ethical governance. The need to accelerate automation and maintain the human-in-the-loop demonstrates broader questions of responsibility and transparency. Next-gen AI for Aerospace Engineering investigates the transformative role of GenAI within aerospace engineering, examining its shift from conventional workflows toward more AI-driven solutions in design, manufacturing, and maintenance. It emphasizes GenAI’s emerging ability to automate repetitive mundane tasks, reduce design complexity, and optimize engineering pipelines. The report underscores the need for validation methods that must align AI-generated outputs with physics-informed models, integration with legacy engineering tools (e.g., computational fluid dynamics, finite element analysis, digital twins), and
Khan, Samir
Drones, or Unmanned Aerial Vehicles (UAVs) pose an increasing threat to military ground vehicles due to their precision strike capabilities, surveillance functions, and ability to engage in electronic warfare. Their agility, speed, and low visibility allow them to evade traditional defense systems, creating an urgent need for advanced AI-driven detection models that quickly and accurately identify UAV threats while minimizing false positives and negatives. Training effective deep-learning models typically requires extensive, diverse datasets, yet acquiring and annotating real-world UAV imagery is expensive, time-consuming, and often non-feasible, especially for imagery featuring relevant UAV models in appropriate military contexts. Synthetic data, generated via digital twin simulation, offers a viable approach to overcoming these limitations. This paper presents some of the work Duality AI is doing in conjunction with the Army’s Program Executive Office Ground Combat Systems (PEO GCS
Mejia, FelipeShah, SunilYoung, Preston C.Brunk, Andrew T.
In the ever-evolving landscape of ground vehicle development, the integration of Artificial Intelligence (AI), Machine Learning (ML), and Software Production Factory (SPF) technologies offers unprecedented opportunities to accelerate rapid prototyping processes. This whitepaper explores the synergistic potential of these cutting-edge technologies, detailing their transformative impact on the design, development, and deployment of advanced ground vehicle systems. By leveraging AI and ML algorithms, engineers can automate complex design tasks, predict performance outcomes, and optimize configurations with unparalleled precision. Enhanced modeling and simulation capabilities driven by AI and ML, combined with Digital Engineering threads and twin, allow for more accurate virtual testing environments, reducing the need for physical prototypes and accelerating the iterative design process. This whitepaper serves as a crucial guide for stakeholders seeking to harness the full potential of
Griffin, KevinKanon, RobertRinaldo, AnthonyKouba, Russ
This paper presents a model-based systems engineering (MBSE) and digital twin approach for a military 6T battery tester. A digital twin architecture (encompassing product, process, and equipment twins) is integrated with AI-driven analytics to enhance battery defect detection, provide predictive diagnostics, and improve testing efficiency. The 6T battery tester’s MBSE design employs comprehensive SysML models to ensure traceability and robust system integration. Initial key contributions include early identification of battery faults via impedance-based sensing and machine learning, real-time state-of-health tracking through a synchronized virtual battery model, and streamlined test automation. Results indicate the proposed MBSE/digital twin solution can detect degradation indicators (e.g. capacity fade, rising internal impedance) earlier than traditional methods, enabling proactive maintenance and improved operational readiness. This approach offers a reliable, efficient testing
Sandoval, Roman
The integration of digital twins within a digital thread framework offers significant benefits for managing Army ground and surface water vehicles. This paper examines how digital twins can enhance lifecycle management, operational efficiency, and maintenance for mature and new military vehicle programs. Scalable and cost-effective implementation with layered capabilities allows organizations to start with a cost-effective foundational model and phase in additional layers of capability over time. This phased approach allows you to expand your digital twin capabilities as program budgets permit, ensuring that you can adapt to evolving requirements without overwhelming upfront investment. For established programs, digital twins enable real-time monitoring, predictive analytics, and data-driven decisions, improving resource allocation and cutting costs. For new programs, they speed up prototyping, integrate modern technologies, and enhance training capabilities. Case studies demonstrate
Gonzalez, Troy A.
To achieve Army modernization plans, advanced approaches for testing and evaluation of autonomous ground systems and their integration with human operators should be utilized. This paper presents a framework for developing digital twins at the subsystem level using heterogeneous modeling and simulation (M&S) to address the challenges of manned-unmanned teaming (MUM-T) in operational environments. Focusing on the interplay between robotic combat vehicles (RCVs) and human operations, the framework enables evaluation of soldiers’ cognitive loads while managing tasks such as maneuvering robotic systems, interacting with aided target detection, and engaging simulated adversaries. By employing subsystem-level digital twins, we aim to isolate and control key variables, enabling a detailed assessment of both systems’ performance and operator effectiveness. Through realistic operational scenarios and human-machine interface testing, our approach may help identify optimal solutions for soldier
Van Emden, KristinStrickland, JaredWhitt, JohnFlint, BenjaminMa, LeinMcDonnell, JosephBergin, DennisHuynh, KevinNolta, LukasSong, JaeWeber, KodyGates, BurhmanBounker, PaulMadak, Joseph T.
Vehicle behavior is strongly influenced by tire performance, as tires serve as the primary interface between the vehicle and the road surface. Since identical vehicles equipped with different tire sets—or even the same tires operating under varying thermal and wear conditions—can exhibit significantly different handling characteristics, this study aims to quantify their impact on both steady-state and transient cornering responses through a dedicated evaluation methodology. To demonstrate the generalization of the proposed approach, three completely different validated vehicle digital twins—a passenger car, a sports car, and a formula car—are analyzed in a virtual environment, employing Vi-Car Real Time for vehicle and scenario representations, and RIDEsuite for tire modeling, considering thermal and wear effects. The simulations were designed using a structured design of experiments approach, resulting in 15 predefined combinations of tire temperature and wear states. Results show
Aratri, RobertoRomagnuolo, FabioDe Pinto, StefanoFarroni, FlavioDe Bellis, SergioBottiglione, FrancescoMantriota, GiacomoSakhnevych, Aleksandr
On the path to the decarbonization of the transport sector, the development of electric vehicles (EVs) is crucial to meeting the targets set by international regulatory bodies. EVs operate with zero tailpipe emissions and offer high energy efficiency and flexibility; however, challenges remain in achieving a fully sustainable electricity supply. In this context, powertrain design plays a fundamental role in determining vehicle performance and mission feasibility, which are strongly influenced by operating conditions and application characteristics, such as driving profiles and ambient temperature. A key challenge is the optimal sizing of components, particularly the battery pack and the electric motor. Therefore, a structured and methodological approach to powertrain design is essential to ensuring an optimal configuration. To this end, the project focuses on an integrated approach based on a master-and-slave modeling framework applied to a light-duty commercial vehicle at two levels
Bartolucci, LorenzoCennamo, EdoardoGrattarola, FedericoLombardi, SimoneMulone, VincenzoTribioli, LauraAimo Boot, Marco
Knowing the magnetic flux inside an electric machine can provide valuable information, as it allows for monitoring the actual behavior of the motor during operation. This leads to more accurate torque delivery and enables prognostic and state-of-health analyses. By integrating Hall-effect sensors inside an e-motor, it is possible to measure the magnetic flux and gain all the benefits from this information, such as accurate torque, rotor position and speed, and magnets' temperature. This paper describes the design of an e-motor with an integrated flux sensing array (ISA), including all surrounding models and software solutions for efficient motor control, integrating health monitoring and failure prevention. The focus is on the analyses performed to estimate the magnetic flux linkage and determine the optimal sensor placement, the control architectures that can benefit from a more accurate flux estimation, and the design of the e-machine to integrate the flux sensors. The aim is to
Capitanio, AlessandroSala, GiadaEsmaeilnia, AliGarcia de Madinabeitia, InigoPastore, AndreaTranchero, MaurizioFranceschini, GiovanniSaur, Michael
With the rapid development of new energy vehicles, high-power charging technology has become an effective way to meet the fast-charging needs of electric vehicles. Temperature control of charging cables is crucial for the safety and efficiency of charging. This article aims to develop finite element method (FEM)-ML to predict the temperature field of the charging cable. First, the initial ambient temperature and maximum current were set as the main influencing factors, and a dataset including various charging parameters and cable temperature fields was built by FEM based on a two-factor, four-level orthogonal design. Then, surrogate models based on the Bayesian optimization (BO) algorithm, multilayer perceptron (MLP) model, and extreme gradient boosting (XGB) model were established to predict the temperature field distribution of high-power charging cables. The results indicated that the XGB model had better prediction performance than the MLP model, with average values of MSE, RMSE
Li, XilinZhan, ZhenfeiFan, FuhaoFu, YunyouShen, YunlongPu, LiangxiZhou, QiTang, Weiqin
We present DISRUPT, a research project to develop a cooperative traffic perception and prediction system based on networked infrastructure and vehicle sensors. Decentralized tracking and prediction algorithms are used to estimate the dynamic state of road users and predict their state in the near future. Compared to centralized approaches, which currently dominate traffic perception, decentralized algorithms offer advantages such as greater flexibility, robustness and scalability. Mobile sensor boxes are used as infrastructure sensors and the locally calculated state estimates are communicated in such a way that they can augment local estimates from other sensor boxes and/or vehicles. In addition, the information is transferred to a cloud that collects the local estimates and provides traffic visualization functionalities. The prediction module then calculates the future dynamic state based on neurocognitive behavior models and a measure of a road user's risk of being involved in
Beutenmüller, FrankBrostek, LukasDoberstein, ChristianHan, LongfeiKefferpütz, KlausObstbaum, MartinPawlowski, AntoniaRössert, ChristianSas-Brunschier, LucasSchön, ThiloSichermann, Jörg
Electric vehicles are no longer a rarity on Europe’s streets. But battery electric vehicles (BEVs) still have a long way to go to be the dominant vehicle type on the streets. In the last years, not only has the number of passenger cars risen, but also the number of electric trucks and heavy-duty vehicles. In 2023 electric trucks have share of 1.5% in the market. [1, 2] For the truck industry higher charging powers are even more important. Due to European regulations drivers of vehicles with more than 3.5t weight or buses with more than 10 passengers must rest for 45 minutes after 4.5 hours of drive. [3] Therefore, higher charging powers were needed, and the Megawatt Charging System (MCS) standard was developed. The voltage level goes up to 1250 V and currents of 3000 A are defined. [4] This allows the battery of heavy-duty vehicles to be completely charged within the driving breaks. As with the upcoming MCS standard, the charging power increases, also the failure risk rises. Higher
Grund, CarolineReuss, Hans-Christian
In the era of Industry 4.0, the maintenance of factory equipment is evolving with new systems using predictive or prescriptive methods. These methods leverage condition monitoring through digital twins, Artificial Intelligence, and machine learning techniques to detect early signs of faults, types of faults, locations of faults, etc. Bearings and gears are among the most common components, and cracking, misalignment, rubbing, and bowing are the most common failure modes in high-speed rotating machinery. In the present work, an end-to-end automated machine learning-based condition monitoring algorithm is developed for predicting and classifying internal gear and bearing faults using external vibration sensors. A digital twin model of the entire rotating system, consisting of the gears, bearings, shafts, and housing, was developed as a co-simulation between MSC ADAMS (dynamic simulation tool) and MATLAB (Mathematical tool). The gear and bearing models were developed mathematically, while
Rastogi, SarthakSinghal, SrijanAhirrao, SachinMilind, T. R.
A cutting-edge EV powertrain NVH laboratory has been established at Dana Incorporated’s world headquarters in Ohio, significantly enhancing its capabilities in EV powertrain NVH development. This state-of-the-art, industry-leading facility is specifically designed to address diverse NVH requirements for EV powertrain development and validation processes. This capability substantially reduces development time for new drivetrain systems. Key features of the laboratory include a hemi-anechoic chamber, two AC asynchronous load motors, an acoustically isolated high-speed input motor, and two battery emulators capable of accommodating both low and high-voltage requirements. The NVH laboratory enables engineers to evaluate system performance and correlate results with digital twin models. This capability supports the optimization of NVH characteristics at both the system and component levels, as well as the refinement of CAE models for enhanced design precision. This paper details the design
Cheng, Ming-TeZugo, Chris
Helicopter vibrations, primarily generated by the main rotor-gearbox assembly, are a major source of concern due to their impact on structural integrity, cockpit instrument durability, and crew comfort. These vibrations are mainly transmitted through the gearbox’s rigid support struts to the fuselage, leading to increased cabin noise and potential damage to critical components. This paper presents a solution for vibration mitigation which involves replacing traditional gearbox support struts with low-weight, high-performance active dampers. Developed by Elettronica Aster S.p.A., these active dampers are designed as electro-hydraulic actuators embedded within a compliant structure. The parallel nested configuration of the system enables high power densities and effective vibration control, significantly reducing the transmission of harmful vibrations to the fuselage. The comprehensive model-based design process is detailed, describing the development and use of a high-fidelity physics
Bertolino, Antonio CarloSorli, MassimoPorro, Paolo GiovanniGalli, Claudio
Reeve, TammyPhillips, Paul
Electric motors are critical components in Electric Vehicle (EV) & industrial applications. In case of EVs electric motor has a direct impact on the functionality, range and general user experience. Traditional maintenance procedures have several major limitations such as, leaving no choice but to use the expensive warranty claims, restricted predictive maintenance, unavailability of useful data, reducing resale value, and ultimately poor customer satisfaction. The process of building a virtual duplicate of an actual motor that can replicate the physical system in real time is known as the Digital Twin (DT) technology. Here, the DT technology-based monitoring and maintenance is initiated on permanent magnet synchronous motor (PMSM) used in traction, thus helping to overcome the drawbacks of traditional maintenance system. To provide a holistic approach to real time motor monitoring, motor management, ensuring enhanced reliability, efficiency, and predictive maintenance capabilities
Valiyil, RinshaR, BharathNair, AnushPuthiyapurayil, ShamalRavi, Reshma
Interest in Battery-Driven Electric Vehicles (EVs) has significantly grown in recent years due to the decline of traditional Internal Combustion Engines (ICEs). However, malfunctions in Lithium-Ion Batteries (LIBs) can lead to catastrophic results such as Thermal Runaway (TR), posing serious safety concerns due to their high energy release and the emission of flammable gases. Understanding this phenomenon is essential for reducing risks and mitigating its effects. In this study, a digital twin of an Accelerated Rate Calorimeter (ARC) under a Heat-Wait-and-Seek (HWS) procedure is developed using a Computational Fluid Dynamics (CFD) framework. The CFD model simulates the heating of the cell during the HWS procedure, pressure build-up within the LIB, gas venting phenomena, and the exothermic processes within the LIB due to the degradation of internal components. The model is validated against experimental results for an NCA 18650 LIB under similar conditions, focusing on LIB temperature
Gil, AntonioMonsalve-Serrano, JavierMarco-Gimeno, JavierGuaraco-Figueira, Carlos
Following early adoption, the BEV market has shifted towards a mass market strategy, emphasizing on crucial attributes, such as system cost reduction and range extension. System efficiency is crucial in BEV product development, where efficiency metric influenced greatly vehicle range and cost. For instance, higher iDM efficiency reduces the need for larger battery, cutting cost, or extends range with the same battery size. BorgWarner adopted Digital Twin technology to optimize Integrated Drive Module (iDM) within a vehicle ecosystem. Digital Twin comprises high-fidelity physics based numerical tool suites offering greater degree of freedom to engineers in designing, sizing, optimizing a component versus system benefit tradeoff, thus enabling most efficient product design within economic constraints. BorgWarner’s Analytical System Development (ASD) plan used as framework provides a global unified process for tool development and validation, ensuring the digital print of a real product
Bossi, AdrienBourniche, EricLeblay, ArnaudDavid, PascalNanjundaswamy, Harsha
Electric vehicles rely on accurate estimation of battery states to operate safely and efficiently. Traditionally, the state estimation is pack level and based on empirical models developed to capture the dynamics of a representative battery pack and hence falls short in accounting for cell-to-cell variations. These variations become more pronounced as the cells age within a battery pack under non-homogeneous mechanical, thermal, manufacturing, and electrical conditions. It is challenging to adapt the traditional physics-based model to changing battery dynamics in real-time. To improve the state estimation at the cell level, a data-driven approach utilizing streamed data from vehicles enabled by connectivity has been shown in this paper. While traditional data-driven approaches result in large models and require large quantities of data for training, the proposed method relies on combining the underlying physics of the electrochemical model with novel data-driven modeling techniques
Gupta, ShobhitHegde, BharatkumarHaskara, IbrahimShieh, Su-YangChang, Insu
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
Manvi, PranavSuber II, DarrylGriffith, KaitlynTurner, CameronCastanier, Matthew P.Wagner, John
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