The virtual twin-component

Do you know what a hybrid twin is? A Hybrid Twin is constituted of 3 main components:

  • A Virtual twin-component consists of a parametric model that simulate the outputs of a dynamic system for a given set of parameters. This twin model can be reduced to cope with real time constraints, i.e., a separated and approximated representation of the solution that can be particularized for any combination of parameters within the parametric space of interest.
  • Some sensors allow real-time measurement of quantities of interest on the system operating in the real world.
  • A component able to build in real-time a model of the gap observed between the sensor’s measurements and the Virtual Twin. This gap is also called the ignorance of the Virtual Twin.

The association of these 3 components gives a dynamic system able to correct in real-time the Virtual Twin to enforce it to match the monitored data, allowing to take into account unplanned events/behaviors that were not considered in the Virtual Twin building. Such behavior allows the development of many applications such as embedded hybrid models deployed at the machine level, enabling real-time piloting prediction/control system (Hybrid Twin Decision Support), or decision support solution prognostics based on a simulated drift over time (Hybrid Twin Embedded).

ESI-Group’s main contribution to the MORPHO project consists of providing the Virtual Twin component of the RTM process. The approach to build this Virtual Twin requires several steps:

  1. Definition of the parametric space of interest.
  2. Different numerical simulations have to be carried out and a selection of options of interest.
  3. The real-time parametric solution for obtaining the model response will be obtained.

How is ESI working on the twin component?

PAM-RTM, the resin molding software module within PAM-COMPOSITES is used to simulate the resin injection or the resin infusion of a preform. PAM-RTM can model a wide range of processes (RTM, VARI, CRTM, Light-RTM, HP-RTM…) and in this project, it will be used to simulate the classical RTM process of the FOD panel.

PAM-RTM can help to mitigate RTM manufacturing defects and improves product quality, upfront in the product development process, before cutting any tools, due to the optimization of the following process parameters:

  • Injection/infusion strategy (choice of LCM – Liquid Composite Molding – process).
  • Injection pressure or flow rate.
  • Temperature cycle (tool and resin).
  • Location of injection gates, vents, and vacuum ports.
  • Type and positioning of the flow media.

But the applications on the MORPHO project are mainly two:

  1. Using PAM-RTM for RTM process simulation helps to predict possible errors and configure the model better.
  2. To create a reference model for the Virtual Twin.

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