Integrating physical and virtual testing environments into research and development (R&D) is rapidly moving from a cutting-edge concept to standard practice across many industries. Organizations that take this approach gain a variety of benefits that improve efficiency. Among the advantages is the ability to minimize prototype builds, optimize test cell usage, and enable faster design iterations through digital twin technology and data feedback loops between physical testing and engineering models. The most effective R&D testing teams evaluate and prepare for this transition by exploring essential infrastructure needs and optimization strategies that help organizations of all sizes capitalize on these increasingly vital capabilities while reducing costs and environmental impact.
Evolution of R&D Testing Requirements
Technological advancements continue to reduce the time needed to conduct R&D measurements and collect related data from a physical and virtual perspective. Although accelerometers have historically produced accurate surface vibration measurements, due to their fixed mounting, the mass of the accelerometer could influence the results for light-weight objects. Today’s laser vibrometers allow surface vibration to be scanned in a contactless manner, thereby removing the potential for errors from the accelerometer’s mass.
Similarly, achieving the necessary “surface map of sound” traditionally required a rather labor-intensive and time-consuming sound-intensity measurement. Modern sound cameras offer point-and-shoot capabilities using microphone arrays and a camera to capture visual representations of noise levels viewed with a color map overlay almost instantaneously.
Meanwhile, advancements in computing power and computer-aided design (CAD) modeling capabilities provide the ability to take test data, import it into a virtual model, and use that information to “calibrate” the model conducting the analysis. That model can now be digitally modified and utilized to predict outcomes after completing an analysis. This method avoids building multiple prototypes iteratively throughout the process and instead builds an initial prototype based on comprehensive testing in a virtual sense. After attempting different virtual iterations, one optimized physical prototype can be built to validate the expected results. The other advantage of working in this virtual environment is conducting multiple digital variants of one model in parallel to obtain data more quickly.
Key Features of Digital Twin Technology
As a digital replication of physical components, digital twin technology has opened the possibility to iterate and generate data while intermittently comparing that data to a physical test to represent a “single source of truth.” The capability to iterate multiple model variants in parallel offers accelerated development cycles, reducing the number of days to achieve a different final product. As a result, the number of physical prototypes that need to be built on the R&D side is significantly reduced, and less time is spent in a test environment conducting measurements. What was once a time-consuming element of prototype construction and prototype testing can be taken out of the equation altogether, allowing for an accelerated project pace. Although it has not yet become standard practice, digital twin modeling has proven effective in various applications, including the analysis of high-voltage power transformers, high-speed train voltage systems, and Car-as-a-Service architecture.
Implementation of the digital twin or virtual testing involves a joint effort between product engineering and product testing personnel because of a shared need for relevant data. By fostering harmonization among test and product engineers, analyses can be performed on calibrated models to generate insights based on practical experience in a test laboratory. In turn, teams are more likely to predict expected outcomes or anticipate what the results could resemble to reach a solution with fewer iterations.
Establishing an Effective Infrastructure
According to the Business Research Council, the digital twin market is forecasted to grow from $29.06 billion in 2025 to $99.2 billion in 2029. As technology advances, a trend toward virtual analysis is also anticipated, with less focus on physical testing. Organizations can proactively recognize the need to have these design tools available to take this type of digitalization to the next level.
One significant caveat to committing to a virtual style of R&D testing is preparing for an influx of significant amounts of generated data that will need to be stored in a format widely accessible to project stakeholders. This storage requires an infrastructure implemented to process and store all the information, whether the storage occurs on-premises or within the cloud. Software compatibility is ultimately determined by data derived from R&D development testing being ported into the virtual environment space. Regardless of the format—text file, spreadsheet, or other proprietary output of data—it’s essential for the information to be readable through the virtual model.
Fostering a culture of accessibility supports collaboration in project management, but it also underscores the need for robust cybersecurity measures. Digital twin technologies strengthen cybersecurity threat modeling and incident response by creating virtual replicas of an organization’s data and IT infrastructure, allowing potential threats to be simulated and analyzed in a controlled environment.
Options are available for organizations to purchase a full suite of software that offers the potential of physically testing in the field and then feeding that data into the developed digital model. This investment assists decision-makers and stakeholders on capital and equipment projects while instilling confidence and alleviating the need to collect data that must be converted into different formats during post-processing. For example, the process for 3D scanning and modeling tools typically begins with the identification of critical systems that affect data collection or other vital processes, and an in-depth understanding of the facility infrastructure required to support them. The output of the 3D scan replicates a physical structure or device and can become the basis of a digital model.
Review of Related Use Cases
A pair of notably innovative projects illustrates how digital advancements impact organizations in various ways. At Siemens Digital Industries Software, a computer software organization based in Plano, TX, specialized 3D and 2D product lifecycle management software assists clients in digitally transforming their operations through the use of a scalable data acquisition system. This process facilitates flexibility in collecting sound and vibration data, regardless of project size.
An end-of-line tractor test lab at AGCO Corp., an agricultural machinery manufacturer in Jackson, MN, underwent a ventilation system upgrade to include air conditioning. Through several design iterations, a final solution meeting all desired outcomes was virtually achieved. The remodeled ventilation system offers a range of temperature and humidity operating points controlled and fully accessible by test operations.
As current technologies become increasingly sophisticated, design styles will likely focus less on testing and more on conducting virtual analysis. It is important for organizations to be proactive by recognizing the need to invest in advanced design tools to ensure they can bring their digitalization work to the next level. With modern software built to perform flow, sound, and structural analyses, more products can now be designed exclusively in a virtual environment to get to the finished product.
About the Author
Randy Rozema is a Principal and Director of Acoustics & Vibration for ACS Inc., Verona, WI. ACS engineers, integrates, and builds technically complex equipment, controls, and facilities for industry-leading companies in markets including automotive, aerospace, energy, chemical, manufacturing, and more. ACS specializes in control systems, custom machines, testing solutions, automation, and production systems, as well as the design and construction of integrated facilities. For more information, please call (608) 663-1590 or visit http://www.acscm.com.