The 3DEXPERIENCE Platform enhances the accuracy and functionality of virtual twins
Published on : Friday 02-08-2024
Philippe Bartissol, VP, Industrial Equipment Industry, Dassault Systèmes.
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What are the highlights of the collaboration with OMRON in the area of virtual twins at Hannover Messe 2024?
This year at Hannover Messe, Dassault Systèmes, in collaboration with OMRON, displayed a state-of-the-art shop floor featuring mobile, autonomous robots that operate across four distinct stations of the production process. This innovative solution has been designed for decision-makers and managers within the manufacturing industry, offering a glimpse into how virtual twin experiences can revolutionise factory planning, operation, efficiency, and flexibility.
Streamlined System Planning in the Pre-Sales Phase
One of the standout features of the showcase is the ability to plan production lines using the 3DEXPERIENCE platform. By creating detailed 3D models, manufacturers can ensure that new machines and mobile robots are seamlessly integrated into existing layouts. This includes optimal positioning for power supplies and walking paths, thus maximising space utilisation and operational efficiency. The flexibility of the virtual twin allows for dynamic robot simulations and the design of innovative workflows, significantly enhancing the planning process.
Virtual Commissioning for Smooth Integration
To facilitate a seamless transition from planning to operation, the virtual twin enables the simulation of workflows before physical commissioning. This pre-emptive approach allows for the identification and rectification of errors and bottlenecks in the control process. As a result, companies can benefit from reduced installation times and efficient processes, ensuring that operations commence smoothly and without unexpected delays.
Advanced Management of Operations
As the fleet of mobile robots expands, so does the complexity of monitoring and managing their operations. The 3DEXPERIENCE platform’s virtual twin is a comprehensive control centre, aggregating real-time operating data, key performance indicators, and material information. This centralised overview empowers managers with the insights needed to make informed decisions, optimise workflows, and maintain high operational efficiency.
Enhanced After-Sales Service
Virtual twins continue to provide value through tailored, data-driven, and sustainable maintenance solutions, leveraging artificial intelligence and machine learning. Sensor data is analysed to predict and prevent potential failures, enabling proactive maintenance strategies that minimise downtime. Additionally, augmented reality (AR) technology can be integrated to enhance diagnostic and repair processes. By overlaying virtual information onto the real-world view seen through a tablet PC or smartphone, AR facilitates precise diagnoses and accelerates repair times.
This collaborative showcase between Dassault Systèmes and OMRON not only demonstrates cutting-edge technological advancements, but also provides practical insights into how these innovations can be effectively implemented to transform manufacturing operations. By embracing virtual twin experiences, manufacturers can achieve unprecedented levels of planning accuracy, operational efficiency, and proactive maintenance, paving the way for the factories of the future.
How does the 3DEXPERIENCE Platform facilitate the creation and utilisation of virtual twins for predictive maintenance and lifecycle management of assets?
Virtual twins represent an ideal solution across various sectors, objects, and processes where optimisation and innovation are paramount. These digital replicas offer unparalleled insights and capabilities, enabling organisations to push the boundaries of efficiency and creativity.
Traditionally, the purchase of a machine culminated in ownership transfer once all financial obligations were settled. However, emerging models now foster a collaborative approach between customers and suppliers, wherein costs and revenues are shared. This paradigm shift reduces initial costs for the customer and continuous revenue for the supplier throughout the machine's lifecycle. Jointly bearing development costs through negotiated instalments further strengthens this partnership. It's called Equipment-as-a-Service, e.g. RaaS –Robotics-as-a-Service.
Such collaborative arrangements enable both manufacturers and buyers to determine the most beneficial mutual relationship. A prime example is the joint development of specialised devices, where development costs and subsequent revenues are shared. For instance, the supplier might receive a percentage of each product made and sold using the device. This model is advantageous for both parties: the supplier shares the design costs with the customer, fostering a close collaboration, while the customer benefits from lower initial investments.
For suppliers, this close relationship incentivises maximising the device's availability, accuracy, and speed, as their revenue is directly tied to the performance and output of the equipment. This mutual interest in the success and efficiency of the machinery leads to highly optimised production processes and a more innovative approach to machine development and utilisation. In practice, numerous examples of such close cooperation are already demonstrating significant benefits for both customers and suppliers.
There is a specific interest based on the XaaS model by all equipment suppliers to have control of all operating data of the supplier´s equipment running at the customers' site. “Closing the loop” by collecting and analysing operating data of the shopfloor equipment to permanently improve the product or system on the 3DEXPERIENCE platform by its Virtual Twin, is one significant benefit as a result of the XaaS mode.
Could you elaborate on the role of AI and machine learning in optimising virtual twin simulations and predictions?
A good example is the demo of the Line Analysis of the Hannover Fair Showcase and how to use AI/machine learning:
By that demo, we are showing the power of our predictive maintenance tool to predict future issues. Predictive maintenance is a proactive approach to maintenance that aims to predict equipment failures before they occur, thereby minimising downtime, reducing costs, and optimising maintenance schedules. It relies on data analysis, machine learning algorithms, and sensor technology to monitor the condition of equipment in real time and forecast when maintenance will be required. Predictive maintenance works mostly using data collection and data analysis; advanced analytics techniques, including machine-learning algorithms, are applied to the collected data to identify patterns, trends, and anomalies that may indicate potential equipment failures. These algorithms can detect subtle changes in equipment conditions that human operators may overlook. In the end, this kind of tool allows users to reduce downtime and costs that they need in the factory.
Another example is a Robotics research project years ago, to use AI to self-learn the best picking of goods robots by interconnecting all robots and learning from all robots by machine learning algorithm, to permanently improve the goods picking task. What was done by using real robots in the past can be done now on our platform by testing the machine learning algorithm on the robot.
Can you explain the key features and capabilities of the 3DEXPERIENCE Platform in enabling virtual twins across various industries?
The 3DEXPERIENCE Platform, developed by Dassault Systèmes, plays a pivotal role in enhancing the accuracy and functionality of virtual twins through the seamless integration of IoT data and simulation models. Here’s how it accomplishes this:
Real-Time Data Integration: The platform aggregates real-time data from IoT-enabled devices and sensors installed across the production environment. This data includes critical metrics such as machine performance, environmental conditions, and operational status. By continuously feeding this live data into the virtual twin, the platform ensures that the digital model accurately reflects the current state of the physical system.
Comprehensive Simulation Capabilities: The 3DEXPERIENCE Platform supports advanced simulation tools that allow users to model and analyse various scenarios. By incorporating real-time IoT data, these simulations can account for dynamic changes in the production environment, leading to more accurate predictions and analyses. This capability is crucial for testing new workflows, optimising processes, and anticipating potential issues before they arise.
Enhanced Predictive Maintenance: Integrating IoT data with simulation models enables the platform to perform sophisticated predictive maintenance. By analysing patterns and trends in the sensor data, the virtual twin can predict potential failures and maintenance needs. This proactive approach helps minimise downtime, reduce maintenance costs, and extend the lifespan of equipment.
Improved Decision-Making: The platform’s ability to combine IoT data with simulation results provides a holistic view of the production process. This integrated perspective supports better decision-making by offering insights into the impact of various operational adjustments. Managers can explore different scenarios and their outcomes, leading to more informed and effective strategies.
Real-Time Monitoring and Control: The virtual twin, enriched with real-time IoT data, serves as a comprehensive control center. It allows operators to monitor the status and performance of machines and processes in real-time. This functionality enhances the ability to respond quickly to issues, optimise operations, and ensure consistent product quality.
Collaboration and Innovation: The 3DEXPERIENCE Platform fosters collaboration among different stakeholders by providing a unified environment where they can share and analyse data. This collaborative approach enhances innovation, as teams can work together to refine models, test new ideas, and implement improvements based on real-world data.
Feedback Loop for Continuous Improvement: By continuously integrating IoT data into the virtual twin, the platform creates a feedback loop for continuous improvement. The insights gained from real-time monitoring and simulations can be used to iteratively refine processes, leading to ongoing enhancements in efficiency, productivity, and quality.
In summary, the 3DEXPERIENCE Platform enhances the accuracy and functionality of virtual twins by integrating real-time IoT data with robust simulation models. This integration enables predictive maintenance, improved decision-making, real-time monitoring, and continuous process improvement, thereby driving innovation and efficiency in manufacturing operations.
Are there any use cases of successful implementations of virtual twins using Dassault Systèmes' solutions in the discrete manufacturing area, and the
benefits have they delivered?
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Yes, there are notable use cases of successful implementations of virtual twins using Dassault Systèmes' solutions in the discrete manufacturing area. One prominent example is the German firm Pepperl+Fuchs, which has effectively leveraged the 3DEXPERIENCE platform on the cloud to digitalise its processes and improve its product lifecycle management (PLM).
Pepperl+Fuchs, with nearly 80 years of experience in process automation, specialises in industrial sensors and explosion protection technologies. The company has a diverse range of 50,000 products applied in various manufacturing environments, from refineries to alternative energy plants. The company aimed to fully digitalise its existing processes to enhance efficiency, transparency, and quality across the product lifecycle. The goal was to embrace a data-driven approach, converting data into a common format to build the foundation for virtual twins. This transformation was crucial for providing a single view of data, which had been previously fragmented across more than 100 different software systems, creating silos and hindering collaboration and iteration.
Pepperl+Fuchs selected Dassault Systèmes' 3DEXPERIENCE platform on the cloud to achieve its goals. The platform's capabilities for data management and archiving, along with its unique data model and modern, collaboration-focused interface, made it an ideal choice. The cloud-based nature of the platform also ensured fast deployment, global scalability, and compliance with local legislation. The initial phase involved 200 colleagues from 17 departments to set up the system. First licenses were rolled out to 50 users for validation, with future phases extending the platform to cover the entire innovation chain, involving 2,500 users.
The benefits delivered by this implementation are significant. The 3DEXPERIENCE platform integrated people, processes, product data, and systems, enabling Pepperl+Fuchs to manage products throughout their entire lifecycle. By breaking down data silos, the platform facilitated better collaboration and iteration among different teams. The single source of truth provided by the platform allowed for more efficient business decisions. The cloud-based solution ensured that Pepperl+Fuchs could scale its operations globally while adhering to local regulations. Additionally, the platform enabled secure data sharing with other stakeholders along the value chain without compromising intellectual property.
One of the applications of Pepperl+Fuchs' digital transformation is seen in its R2000 2-D Laser Scanner. This product includes multiple embedded systems and is used for tunnel maintenance by detecting structural anomalies with millimeter precision. The digitalisation efforts have streamlined the product's lifecycle management, enhancing its development and deployment. This use case of Pepperl+Fuchs demonstrates how virtual twins can be successfully implemented in the discrete manufacturing area, showing the significant value that virtual twin technology can bring to complex manufacturing environments.
Other customer cases:
https://www.3ds.com/insights/customer-stories/hyundai-doosan-infracore
https://www.3ds.com/insights/customer-stories/titan-latam-agribusiness
https://www.3ds.com/insights/customer-stories/coorstek-technical-ceramics
How does Dassault Systèmes ensure data security and privacy, especially considering the sensitive nature of virtual twin simulations and operational data?
At Dassault Systèmes, we prioritise security, privacy, and quality at the core of our 3DEXPERIENCE platform operations. We ensure robust data security and privacy through a multi-faceted and proactive cybersecurity management approach. This includes the secure handling and processing of personally identifiable information (PII) and a traceable software development lifecycle to control and monitor software changes effectively. Our platform is powered by ISO-certified management systems, providing a reliable and scalable cloud operation. Specifically, our ISO/IEC 27001:2017 certification covers the design, development, delivery, deployment, cloud operations, and support of the 3DEXPERIENCE platform SaaS. To continuously monitor and mitigate vulnerabilities, we apply comprehensive risk assessment processes based on NIST SP 800-53, ISO/IEC 27001, and ISO/IEC 27701.
Our multi-layer vulnerability management system combines external and in-house systems for identifying, testing, and controlling vulnerabilities. We use network and vulnerability scanners, static code analysis (SAST), dynamic analysis (DAST), intensive manual penetration tests, and private bug bounty programs to identify and address potential threats. By integrating these stringent measures, we ensure the security and privacy of sensitive virtual twin simulations and operational data, providing peace of mind and reliable protection for our clients.
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