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Keywords = Siemens NX

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21 pages, 30447 KiB  
Article
Comparison of Methods for Reconstructing Irregular Surfaces from Point Clouds of Digital Terrain Models in Developing a Computer-Aided Design Model for Rapid Prototyping Technology
by Michał Chlost and Anna Bazan
Designs 2025, 9(4), 81; https://doi.org/10.3390/designs9040081 - 1 Jul 2025
Viewed by 439
Abstract
This article presents a methodology for developing a three-dimensional terrain model based on numerical data in the form of a point cloud, with an emphasis on reducing mesh surface errors and using a surface smoothing factor. Initial surface generation was based on a [...] Read more.
This article presents a methodology for developing a three-dimensional terrain model based on numerical data in the form of a point cloud, with an emphasis on reducing mesh surface errors and using a surface smoothing factor. Initial surface generation was based on a point cloud with a square mesh, and an adopted algorithm for mesh conversion to the input form for the computer aided design (CAD) environment was presented. The use of a bilinear interpolation algorithm was proposed to reduce defects in the three-dimensional surface created in the reverse engineering process. The terrain mapping accuracy analyses were performed for three samples of different geometry using two available options in the Siemens NX program. All obtained surfaces were subjected to shape deviation analysis. For each of the analyzed surfaces, changing the smoothing factor from 0% to 15% did not cause significant changes in accuracy depending on the method adopted. For flat regions, in the Uniform Density (UD) method, the size of the area outside the tolerance was 6.16%, and in the Variable Density (VD) method, it was within the range of 5.01–6%. For steep regions, in the UD method, it was 6.25%, and in the VD method, it was within the range of 5.39–6.47%, while for concave–convex regions, in the UD method, it was 6.5% and in the VD method, it was within the range of 4.96–6.36%. For a smoothing factor value of 20%, a sudden increase in the inaccuracy of the shape of the obtained surface was observed. For flat regions, in the Uniform Density (UD) method, the size of the area outside the tolerance was 69.84%, and in the Variable Density (VD) method, it was 71.62%. For steep regions, in the UD method, it was 76.07%, and in the VD method, it was 80.94%, while for concave–convex regions, in the UD method, it was 56.08%, and in the VD method, it was 62.38%. The developed methodology provided high accuracy in the reproduction of numerical data that can be used for further analyses and manufacturing processes, such as 3D printing. Based on the obtained data, three fused deposition model (FDM) prints were made, presenting each of the analyzed types of terrain geometry. Only FDM printing was used, and other technologies were not verified. Full article
(This article belongs to the Special Issue Design Process for Additive Manufacturing)
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23 pages, 3277 KiB  
Article
Behaviour-Based Digital Twin for Electro-Pneumatic Actuator: Modelling, Simulation, and Validation Through Virtual Commissioning
by Roman Ruzarovsky, Tibor Horak, Richard Skypala, Roman Zelník, Martin Csekei, Ján Šido, Eduard Nemlaha and Michal Kopček
Electronics 2025, 14(12), 2434; https://doi.org/10.3390/electronics14122434 - 14 Jun 2025
Viewed by 614
Abstract
A digital twin is an effective tool for the design, testing, and validation of control strategies for electro-pneumatic actuators in industrial automation. This study presents and compares three different digital twin models of a pneumatic cylinder with varying levels of physical fidelity—from basic [...] Read more.
A digital twin is an effective tool for the design, testing, and validation of control strategies for electro-pneumatic actuators in industrial automation. This study presents and compares three different digital twin models of a pneumatic cylinder with varying levels of physical fidelity—from basic discrete control, through analogue control without pneumatic dynamics, to a complex model simulating pressure, friction, and airflow. The experiments were conducted using the Siemens NX Mechatronics Concept Designer, integrated with the SIMIT emulation platform and a PLC control system via the standardized OPC UA protocol. The main objective was to evaluate simulation accuracy, model flexibility for testing various control strategies, and the ability of the digital twin to reflect changes in PLC algorithms. The results showed that while simple models are suitable for verifying basic logic, only advanced models can realistically replicate the dynamic behaviour of pneumatic systems, including delay phases and pressure influence. A comparison with the experimental study by Jiménez confirmed a strong correlation between the simulated and actual actuator behaviour. In future work, the developed control algorithm will be connected to a physical cylinder to further validate the models and refine control strategies under real-world conditions. Full article
(This article belongs to the Special Issue Digital Twinning: Trends Challenging the Future)
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42 pages, 16651 KiB  
Article
Internet of Things-Cloud Control of a Robotic Cell Based on Inverse Kinematics, Hardware-in-the-Loop, Digital Twin, and Industry 4.0/5.0
by Dan Ionescu, Adrian Filipescu, Georgian Simion and Adriana Filipescu
Sensors 2025, 25(6), 1821; https://doi.org/10.3390/s25061821 - 14 Mar 2025
Cited by 1 | Viewed by 1219
Abstract
The main task of the research involves creating a Digital Twin (DT) application serving as a framework for Virtual Commissioning (VC) with Supervisory Control and Data Acquisition (SCADA) and Cloud storage solutions. An Internet of Things (IoT) integrated automation system with Virtual Private [...] Read more.
The main task of the research involves creating a Digital Twin (DT) application serving as a framework for Virtual Commissioning (VC) with Supervisory Control and Data Acquisition (SCADA) and Cloud storage solutions. An Internet of Things (IoT) integrated automation system with Virtual Private Network (VPN) remote control for assembly and disassembly robotic cell (A/DRC) equipped with a six-Degree of Freedom (6-DOF) ABB 120 industrial robotic manipulator (IRM) is presented in this paper. A three-dimensional (3D) virtual model is developed using Siemens NX Mechatronics Concept Designer (MCD), while the Programmable Logic Controller (PLC) is programmed in the Siemens Totally Integrated Automation (TIA) Portal. A Hardware-in-the-Loop (HIL) simulation strategy is primarily used. This concept is implemented and executed as part of a VC approach, where the designed PLC programs are integrated and tested against the physical controller. Closed loop control and RM inverse kinematics model are validated and tested in PLC, following HIL strategy by integrating Industry 4.0/5.0 concepts. A SCADA application is also deployed, serving as a DT operator panel for process monitoring and simulation. Cloud data collection, analysis, supervising, and synchronizing DT tasks are also integrated and explored. Additionally, it provides communication interfaces via PROFINET IO to SCADA and Human Machine Interface (HMI), and through Open Platform Communication—Unified Architecture (OPC-UA) for Siemens NX-MCD with DT virtual model. Virtual A/DRC simulations are performed using the Synchronized Timed Petri Nets (STPN) model for control strategy validation based on task planning integration and synchronization with other IoT devices. The objective is to obtain a clear and understandable representation layout of the A/DRC and to validate the DT model by comparing process dynamics and robot motion kinematics between physical and virtual replicas. Thus, following the results of the current research work, integrating digital technologies in manufacturing, like VC, IoT, and Cloud, is useful for validating and optimizing manufacturing processes, error detection, and reducing the risks before the actual physical system is built or deployed. Full article
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25 pages, 5724 KiB  
Article
Digital Twin Integration for Workforce Training: Transforming SMEs in the Ornamental Stone Industry
by Carlos E. Cremonini, Carlos Capela, Agostinho da Silva, Marcelo C. Gaspar and Joel C. Vasco
Systems 2025, 13(2), 120; https://doi.org/10.3390/systems13020120 - 13 Feb 2025
Viewed by 1543
Abstract
Digital twin technology offers immersive and cost-effective solutions for workforce training, yet its practical implementation within SME training frameworks remains limited. This study develops and evaluates the Digital Twin Framework for Workforce Training (DT4WFT), addressing key challenges such as resource constraints and precision [...] Read more.
Digital twin technology offers immersive and cost-effective solutions for workforce training, yet its practical implementation within SME training frameworks remains limited. This study develops and evaluates the Digital Twin Framework for Workforce Training (DT4WFT), addressing key challenges such as resource constraints and precision through tools like Siemens NX Mechatronic Concept Design (MCD) and StoneCUT@Line®. Employing a mixed-methods approach, qualitative insights from managers, and quantitative analysis demonstrated the framework’s potential to enhance operator performance, improve efficiency, and reduce lead times. However, the validation was based solely on managerial perceptions, as the framework has not yet been implemented in real-world settings. Statistical analysis confirmed strong correlations between the framework’s perceived implementation and improved training outcomes, highlighting its scalability and adaptability. Future research should focus on practical implementation, cross-industry applications, and longitudinal studies to evaluate sustained impacts, ensuring the DT4WFT framework’s broader relevance and effectiveness in workforce development. Full article
(This article belongs to the Section Systems Practice in Social Science)
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16 pages, 4013 KiB  
Article
Ultrasonic Sensor Modeling with Support Vector Regression
by Duy Ngoc Dang, Tri Minh Do, Rui Alexandre de Matos Araújo, Khang Hoang Vinh Nguyen and Can Duy Le
Sensors 2025, 25(3), 678; https://doi.org/10.3390/s25030678 - 23 Jan 2025
Viewed by 1109
Abstract
This study proposes a novel approach for predicting the output behaviors of the Pepperl+Fuchs 3RG6232-3JS00-PF ultrasonic sensor. The sensor, integrated into the Festo MPS-PA Didactic System, serves to monitor the water level in a tank, facilitating water extraction to bottles delivered via a [...] Read more.
This study proposes a novel approach for predicting the output behaviors of the Pepperl+Fuchs 3RG6232-3JS00-PF ultrasonic sensor. The sensor, integrated into the Festo MPS-PA Didactic System, serves to monitor the water level in a tank, facilitating water extraction to bottles delivered via a conveyor belt. This modeling approach represents the initial phase in the creation of a digital twin of the physical sensor, providing the capability for users to observe the sensor’s response and forecast its life cycle for maintenance objectives. This study utilizes the Festo MPS-PA Compact Didactic System and support vector regression (SVR) for data acquisition (DAQ), preprocessing, and model training with hyperparameter optimization. The objective of this modeling approach is to establish a digital framework for transition towards Industry 4.0. It holds the potential for creating a digital counterpart of the entire MPS-PA System when combining the proposed sensor modeling technique with computer-assisted design (CAD) software such as Siemens NX in the future. This would enable users to oversee the entire process in a three-dimensional visualization engine, such as Tecnomatix Plant Simulation. This research significantly contributes to the comprehension and application of digital twins in the realm of mechatronics and sensor systems technology. It also underscores the importance of digital twins in enhancing the efficiency and predictability of sensor systems. The method used in this paper involves predicting the rate of change (RoC) of the water level and then integrating this rate to estimate the actual water level, providing a robust approach for sensor data modeling and digital twin creation. The result shows a promising 6.99% error percentage. Full article
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17 pages, 6515 KiB  
Article
Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS
by Frantisek Sedlacek, Tomas Kalina and Martin Stepanek
Materials 2023, 16(15), 5422; https://doi.org/10.3390/ma16155422 - 2 Aug 2023
Cited by 10 | Viewed by 3528
Abstract
This paper presents a novel design methodology that validates and utilizes the results of topology optimization as the final product shape. The proposed methodology aims to streamline the design process by eliminating the need for remodeling and minimizing printing errors through process simulation. [...] Read more.
This paper presents a novel design methodology that validates and utilizes the results of topology optimization as the final product shape. The proposed methodology aims to streamline the design process by eliminating the need for remodeling and minimizing printing errors through process simulation. It also eliminates the repeated export and import of data between software tools. The study includes a case study involving the steering column housing of a racing car, where Siemens NX Topology Optimization was used for optimization, and verification analysis was conducted using the NX Nastran solver. The final solution was fabricated using AlSi10Mg via direct metal laser sintering on a 3D printer and successfully validated under real conditions. In conclusion, this paper introduces a comprehensive design methodology for the direct utilization of topology optimization, which was validated through a case study, yielding positive results. Full article
(This article belongs to the Special Issue Developments in Additive Manufacturing and 3D Printing)
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23 pages, 8261 KiB  
Article
Integrated Aircraft Design System Based on Generative Modelling
by Wojciech Skarka, Rafał Nalepa and Robert Musik
Aerospace 2023, 10(8), 677; https://doi.org/10.3390/aerospace10080677 - 29 Jul 2023
Cited by 6 | Viewed by 3696
Abstract
This article presents the effects of work performed during a software project for generative models and spreadsheets, allowing the quick creation of conceptual models for aircraft. The presented software at the current stage is suitable for the creation of glider representation; however, a [...] Read more.
This article presents the effects of work performed during a software project for generative models and spreadsheets, allowing the quick creation of conceptual models for aircraft. The presented software at the current stage is suitable for the creation of glider representation; however, a modular structure allows for developing and extrapolating the presented application to match the requirements of planes and UAV (unmanned aerial vehicle) design. The subject of this work is a response to the current trends and needs prevailing in the field of CAD (computer-aided design) and aviation. In the initial sections of this paper, theoretical issues related to the work being carried out are introduced, and the methodology for creating software for the construction and verification of the aircraft structure along with the need for interchange between databases of generative models is presented. In the following sections, the concepts and selected solutions for the user interface that supports the knowledge base are presented along with a set of procedures for its operation. Furthermore, a method for database integration with the methods used to determine design features for the developed generative models and the Siemens NX system is introduced. Problems encountered during software development, as well as solution examples for model applications, are specified. The results obtained and the models generated on their basis were tested with a strength analysis using Autodesk Inventor software and analysed in terms of meeting the initial assumptions. In the end, conclusions and observations were formulated resulting from the effects of the work performed during the project. Full article
(This article belongs to the Special Issue Cross-Domain Intelligent Flight Vehicle Design)
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19 pages, 10058 KiB  
Article
Case Study of Additively Manufactured Mountain Bike Stem
by Filip Véle, Michal Ackermann, Jakub Macháček and Jiří Šafka
Materials 2023, 16(13), 4717; https://doi.org/10.3390/ma16134717 - 29 Jun 2023
Cited by 6 | Viewed by 3093
Abstract
This article is focused on a case study of the topology optimisation of a bike stem manufactured by selective laser melting (SLM) additive technology. Topology optimisation was used as a design tool to model a part with less material used for transferring specific [...] Read more.
This article is focused on a case study of the topology optimisation of a bike stem manufactured by selective laser melting (SLM) additive technology. Topology optimisation was used as a design tool to model a part with less material used for transferring specific loads than the conventional method. For topology optimisation, Siemens NX 12 software was used with loads defined from the ISO 4210-5 standard. Post-processing of the topology-optimised shape was performed in Altair Inspire software. For this case study, the aluminium alloy AlSi10Mg was selected. For qualitative evaluation, the mechanical properties of the chosen alloy were measured on the tensile specimens. The design of the new bike stem was evaluated by Ansys FEA software with static loadings defined by ISO 4210-5. The functionality of the additively manufactured bike stem was confirmed by actual experiments defined by ISO 4210-5. The resulting new design of the bike stem passed both static tests and is 7.9% lighter than that of the reference. Full article
(This article belongs to the Special Issue Design and Application of Additive Manufacturing: Volume II)
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17 pages, 7924 KiB  
Article
Method for Tuning the Parameters of Active Force Reducing Building Vibrations—Numerical Tests
by Andrzej Dymarek, Tomasz Dzitkowski, Krzysztof Herbuś, Piotr Ociepka, Andrzej Niedworok and Łukasz Orzech
Energies 2021, 14(24), 8293; https://doi.org/10.3390/en14248293 - 9 Dec 2021
Cited by 1 | Viewed by 1886
Abstract
The paper formulates a method of active reduction of structure vibrations in the selected resonance zones of the tested object. The method ensures reduction of vibrations of the selected resonance zones by determining the parameters of the active force that meets the desired [...] Read more.
The paper formulates a method of active reduction of structure vibrations in the selected resonance zones of the tested object. The method ensures reduction of vibrations of the selected resonance zones by determining the parameters of the active force that meets the desired dynamic properties. The paper presents a method for determining the parameters of the active force by reducing the vibrations of the structure in its resonance zones to a given vibration amplitude. For this purpose, an analytical form was formulated, which will clearly define the dynamic properties of the tested object and the force reducing the vibrations in the form of a mathematical model. The formulated mathematical model is a modified object input function, which in its form takes into account the properties of the active force reducing the vibrations. In such a case, it is possible to use the methods of mechanical synthesis to decompose the modified characteristic function into the parameters of the system and the parameters of the force being sought. In the formulated method, the desired dynamic properties of the system and the vibration reducing force were defined in such a way that the determined parameters of the active force (velocity-dependent function) had an impact on all forms of natural vibrations of the tested system. Based on the formalized method, the force reducing the vibrations of the four-story frame to the desired displacement amplitude was determined. Two cases of determining the active force reducing the vibrations to the desired vibration amplitude of the system by modifying the dynamic characteristics describing the object together with the active force were considered. For both cases, the system’s responses to the oscillation generated by harmonic force of frequencies equal to the first two forms of natural vibrations of the tested system were determined. In order to verify the determined force reducing the vibrations of the object and to create a visualization of the analyzed phenomenon, the building structure dynamics were analyzed with the use of PLM Siemens NX 12 software. The determined force parameters were implemented into the numerical model, in which the tested system was modelled, and the response time waveforms were generated with regard to the considered story. The generated waveforms were compared with the waveforms obtained in the formalized mathematical model for determining the active force reducing the vibrations. The vibrations of the tested numerical model were induced by the kinematic excitation with the maximum amplitude equal to 100 mm, which corresponds to the vibration amplitude during the earthquake with a force equal to level 5 on the Richter scale. Full article
(This article belongs to the Special Issue The KOMTECH-IMTech 2021 Mining Technologies Future)
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18 pages, 11221 KiB  
Article
Assessment of Replacement of Metal Parts by BFRP Composites into a Highly Efficient Electrical Prototype
by Rosa Marat-Mendes, Diogo Ribeira and Luís Reis
J. Compos. Sci. 2021, 5(4), 95; https://doi.org/10.3390/jcs5040095 - 1 Apr 2021
Viewed by 2586
Abstract
This work intends to evaluate the use of epoxy composite materials reinforced with basalt fibers as replacement to metallic mechanical parts of a highly efficient electrical prototype. The analysis of the behavior of the original metallic bracket was made and an optimization process [...] Read more.
This work intends to evaluate the use of epoxy composite materials reinforced with basalt fibers as replacement to metallic mechanical parts of a highly efficient electrical prototype. The analysis of the behavior of the original metallic bracket was made and an optimization process was carried out in order to achieve the most suitable geometry and stacking sequence if produced in composite material. Finite element analysis using Siemens NX12 and experimental tests to the produced composite part were performed in order to access it. It was verified that the total weight of the composite part shows a 45% reduction. The composite part shows a higher deformation than the metallic one due to basalt fiber’s higher flexibility. However, the advantages added by the new component largely compensate for the disadvantages that may have been added without compromising its performance. Obtained results show that the use of basalt fiber reinforced composites as the material of mechanical parts of a highly efficient electrical prototype that is a good alternative. Full article
(This article belongs to the Special Issue Feature Papers in Journal of Composites Science in 2021)
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19 pages, 12390 KiB  
Article
A Numerical Evaluation of Structural Hot-Spot Stress Methods in Rib-To-Deck Joint of Orthotropic Steel Deck
by Nouman Iqbal, Heng Fang, Ahsan Naseem, Muhammad Kashif and Hans De Backer
Appl. Sci. 2020, 10(19), 6924; https://doi.org/10.3390/app10196924 - 2 Oct 2020
Cited by 13 | Viewed by 4728
Abstract
This study numerically investigates the limitations of structural hot-spot stress (SHSS) methods and proposes a guideline for the calculation of hot-spot stresses, which can be used for the better evaluation of fatigue-related problems. Four different SHSS evaluation methods have been applied to the [...] Read more.
This study numerically investigates the limitations of structural hot-spot stress (SHSS) methods and proposes a guideline for the calculation of hot-spot stresses, which can be used for the better evaluation of fatigue-related problems. Four different SHSS evaluation methods have been applied to the rib-to-deck (RD) welded joint in orthotropic steel deck (OSD). These methods are used to calculate SHSS at this critical joint utilizing finite element analyses (FEA) based software Siemens NX.12. The limitations and the accuracy of these methods have been observed under different element types and meshing techniques. Moreover, the effect of the nodal-averaging feature is being studied. Two types of governing stresses are produced by the application of Eurocode fatigue load model-4. Essentially, the bending in deck-plate produces highly non-linear stress at the deck-toe, and the membrane effect in rib-plate generates linear stress at the rib-toe. Guidelines are proposed considering different parameters on these two stress states by applying SHSS evaluation methods. In comparison to other SHSS approaches, the International Institute of Welding (IIW) quadratic stress extrapolation (QSE) method shows better results for solid single-element, and the American Society of Mechanical Engineers (ASME) through thickness stress linearization (TTSL) method stands out in solid cubic-mesh technique. In general, shell elements have more consistent SHSS results as compared to solid elements for both stress states. Full article
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14 pages, 1966 KiB  
Article
Digital Triplet Approach for Real-Time Monitoring and Control of an Elevator Security System
by Michael M. Gichane, Jean B. Byiringiro, Andrew K. Chesang, Peterson M. Nyaga, Rogers K. Langat, Hasan Smajic and Consolata W. Kiiru
Designs 2020, 4(2), 9; https://doi.org/10.3390/designs4020009 - 21 Apr 2020
Cited by 31 | Viewed by 10245
Abstract
As Digital Twins gain more traction and their adoption in industry increases, there is a need to integrate such technology with machine learning features to enhance functionality and enable decision making tasks. This has lead to the emergence of a concept known as [...] Read more.
As Digital Twins gain more traction and their adoption in industry increases, there is a need to integrate such technology with machine learning features to enhance functionality and enable decision making tasks. This has lead to the emergence of a concept known as Digital Triplet; an enhancement of Digital Twin technology through the addition of an ’intelligent activity layer’. This is a relatively new technology in Industrie 4.0 and research efforts are geared towards exploring its applicability, development and testing of means for implementation and quick adoption. This paper presents the design and implementation of a Digital Triplet for a three-floor elevator system. It demonstrates the integration of a machine learning (ML) object detection model and the system Digital Twin. This was done to introduce an additional security feature that enabled the system to make a decision, based on objects detected and take preliminary security measures. The virtual model was designed in Siemens NX and programmed via Total Integrated Automation (TIA) portal software. The corresponding physical model was fabricated and controlled using a Programmable Logic Controller (PLC) S7 1200. A control program was developed to mimic the general operations of a typical elevator system used in a commercial building setting. Communication, between the physical and virtual models, was enabled using the OPC-Unified Architecture (OPC-UA) protocol. Object recognition using “You only look once” (YOLOV3) based machine learning algorithm was incorporated. The Digital Triplet’s functionality was tested, ensuring the virtual system duplicated actual operations of the physical counterpart through the use of sensor data. Performance testing was done to determine the impact of the ML module on the real-time functionality aspect of the system. Experiment results showed the object recognition contributed an average of 1.083 s to an overall signal travel time of 1.338 s. Full article
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12 pages, 13130 KiB  
Article
Process Modelling of Geothermal Drilling System Using Digital Twin for Real-Time Monitoring and Control
by Nahashon O. Osinde, Jean B. Byiringiro, Michael M. Gichane and Hasan Smajic
Designs 2019, 3(3), 45; https://doi.org/10.3390/designs3030045 - 17 Aug 2019
Cited by 21 | Viewed by 8027
Abstract
Currently, Kenya supplies its energy demand predominantly through hydroelectric power, which fluctuates due to poor and unpredictable rainfall in particular years. Geothermal energy is proposed as a clean and reliable energy source in meeting Kenya’s increasing energy demand. During geothermal drilling operations, disruptions [...] Read more.
Currently, Kenya supplies its energy demand predominantly through hydroelectric power, which fluctuates due to poor and unpredictable rainfall in particular years. Geothermal energy is proposed as a clean and reliable energy source in meeting Kenya’s increasing energy demand. During geothermal drilling operations, disruptions due to tool wear and breakages increases the cost of operation significantly. Some of these causes can be mitigated by real-time monitoring of the tool head during operations. This paper presents the design and implementation of a digital twin model of a drilling tool head, represented as a section of a mechatronic assembly system. The system was modelled in Siemens NX and programmed via the TIA portal using S7 1200 PLC. The digital model was programmed to exactly match the operations of the physical system using OPC (open platform communications) standards. These operations were verified through the motion study by simultaneous running of the assembly system and digital twin model. The study results substantiate that a digital twin model of a geothermal drilling operation can closely mimic the physical operation. Full article
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