By Shobha Kulavil
Imagine an aircraft simulation providing insights into engine’s optimum capacity in harsh weather conditions or digitally tracking a spacecraft’s movement in real time and analysing its performance. Thanks to the digital twin technology, such information can be obtained with accuracy and leveraged to enhance the lifespan of the system, predict any potential risk, and optimize performance.
Complex and safety-critical airborne platforms and systems such as aircraft, spacecraft and physical spaces like airports, Maintenance Repair Overhaul (MRO) hubs, and factories can benefit from digital twin as it not only enhances operational efficiency but also helps meet safety and sustainability goals.
Owing to its advantages in aerospace and defence (A&D), digital twin is generating interest among startups in India. Aerospace design firms are integrating advanced technologies such as simulation, artificial intelligence (AI), and 3D to create a digital twin platform for aerospace products and services, which can be deployed in defence and enterprise applications.
Operational capabilities
Historically, virtual models and simulations have not always met A&D complete requirements. The advent of digital twin has introduced simplified design modification and innovation for complex systems of aircraft and defence equipment. It also speeds up the production time for physical components and system integration (such as engines) and physical space planning (such as hangars, MRO centres, airports, and factories) through simulation of equipment flow and factory while ensuring safety and efficiency. As a result, global A&D organizations are contemplating the integration of digital twin technology into their long-term plans across platforms and ecosystem.
For example, digital twin enables a real-time virtual model of an airport where long queues, crowds, and foot traffic flow can be analysed, giving insights into the most-used as well as underused corners. A virtual understanding of people’s movement and designing of spaces can help optimize airports physically, making human interaction and passenger experience more efficient and seamless.
Role in sustainability efforts
The aerospace sector is turning to digital twin to validate designs for eco-friendly alternatives such as electric batteries and hydrogen fuel. With this technology, manufacturers can test various parameters of aircraft design, including aerodynamics, propulsion systems, and material, to identify areas for improvement and enhance fuel efficiency while reducing carbon emissions.
Leading engine manufacturers heavily rely on digital twin for engine health monitoring and predictive analytics to reduce the engine downtime. AI systems and machine learning(ML) help monitor the progress toward lowering the amount of carbon produced by engines and optimizing aircraft engine maintenance. Companies are also using AI to better understand handling of metal scrap and waste from parts when they reach the end of their lifespan.
Impact on the A&D ecosystem
Digital twin offers valuable insights into supply chain operations, fuelling data-driven decision making for enhanced performance. By inferring historical data and advanced data analytics, digital twin creates realistic training scenarios, augmenting the skills and decision-making abilities of operators, pilots, and personnel. This fosters familiarity with complex operational environments, promoting safer and more efficient practices.
By leveraging historical data and advanced analytics, digital twin can also predict and mitigate potential concerns, reducing the risk of unplanned downtime or critical failures during flight operations or at airports. The technology also considers factors such as weather conditions and system failures to evaluate potential risks.
Game-changing synergies
Digital twin is poised to revolutionize the A&D industry, which often has long design and development gestation cycles for new products and even upgrades, eventually leading to high costs. The true power of this technology lies in its ability to accurately simulate every aspect of the creation process, from design to manufacturing and real-world operations in a highly-connected manner. This capability will be a game changer for countries aspiring to become a global hub for A&D innovation and delivery. While India has been making significant investments to transform its A&D landscape, it is imperative for the private sector to actively contribute and build systems that go beyond individual digital replicas and integrate information and resources for the sector seamlessly.
By bridging the gap between the physical and digital realms, digital twin can synergizes data, technologies, and business processes, thus, enabling the transformation of the A&D sector.
(The writer is Vice President and Industry Platform Leader for Aerospace and Defence – India, Capgemini)
