Top 8 Use Cases of Digital Twin in the Automotive Industry
By Umang Dayal
September 24, 2024
With the advent of Industry 4.0, the automotive industry is rapidly moving towards digital technologies of the future. In the growing trend of technology convergence, the automotive industry is driving technologies like AI, IoT, and cloud computing.
With emerging digital technologies, vintage automobile OEMs are working with tech giants to maintain their position. 3D printing, smart vehicles, digital twins, and production line sensors are the key to the automotive industry. In this blog, we will explore the top 8 use cases of digital twins in the automotive industry.
Digital twin technology is the most emerging technology in the field of digital modeling in Industry 4.0. From performance modeling to real-time predictive modeling, digital twins not only create a digital representation of a physical object but also provide continuous information flow from and to the physical object. The market is set to grow at a CAGR of 61.3% between 2023 and 2028.
Enhancing Design and Development Processes
Optimization of the manufacturing process and enhanced design and development is the most crucial part, apart from the production process itself. Being able to identify errors in the design and correct these at the design stage has a major influence, and that is what Digital Twin does.
The tool addresses problems from the initial stage of the project with the correct location of manufacturing equipment to the modification and elimination of waste in sub-delivery manufacture from suppliers. Optimizing the supply chain control procedure can also be a use case for the digital twin in aerospace design. It has been one of the first aspects of digital twins in the automotive industry, ensuring not only fault testing and elimination but also optimizing the end-to-end design and production process.
Optimizing Manufacturing and Production Operations
Streamlining and optimizing manufacturing and production operations is one of the key use cases of digital twins in the automotive industry. The use of a virtual representation of machines, assembly lines, and facilities speeds up the optimization of performance and processes. It significantly reduces the time and effort required for implementing changes.
The ability to run simulations of the complete production process allows engineers to determine an optimal assembly sequence and avoid clashes in high component density areas. It also helps to estimate cycle times and utilize digital analysis to adjust buffer sizes and minimize waiting times, improving production efficiency further. The detailed digital model of the shop floor and equipment can be used in the training and development of the production teams. Virtual machines and production lines are also becoming a part of the digital factory technology, which sets a foundation for Industry 4.0.
A digital representation of the equipment, connected to the internet, exposes the current status and all the relevant data for analytics and maintenance. It makes it easier and quicker to monitor the health of the machine, predict the possible failures long before they could lead to downtime, and avoid expensive unplanned stoppages. The automated analysis of connected devices helps to plan maintenance with fewer checks and more focused inspections and repairs. This also includes checking that the parts made on the machines fit other components perfectly, as they are part of the digital twin of the finished production. This becomes especially vital when different production sites work on varying parts of a single product.
Improving Predictive Maintenance and Asset Management
The automotive industry is also using digital twin technology to gather real-time data and simulation imagery, which is being used in predictive maintenance practices. A digital replica of every vehicle model is filled up with machinery information and maintenance records. The software constantly receives data from installed chip sensors on live vehicles about various parts, conditions, and status. It then promptly mines the data for early signs of breakdown or underperformance. The moment an issue is suspected, the software drafts a comprehensive report detailing which part requires attention. The report is then transferred to a mechanic who services the vehicle before any foreseeable major loss occurs. Through predictive maintenance, it is additionally possible to utilize accurate simulations of the parts and their surroundings to maximize the life of maintenance parts and predict which part might fail soon. Consequently, OEMs can reduce the amount of money spent on warehousing maintenance parts to minimum necessary levels of up to 25% through 2032.
This technology also enables the automotive industry to visualize and simulate the factory to review real assets and real-time data. In summary, this use case offers the creation and visualizing a digital factory compared to the actual one, predicting potential faults and enabling the automotive industry to perform proactive maintenance for predictable downtimes, building performance models, and simulating the best directions for performing proactive maintenance to increase part lifespan.
Enhancing Driver and Passenger Safety
The concept of the digital twin itself is directly related to safety in the automotive industry. By creating a digital twin, manufacturers can run different simulations to ensure safety compliance concerning all sorts of conditions. This includes crash simulations, which allow automotive manufacturers to build more robust car designs that can withstand more extreme scenarios while protecting the passenger and the driver.
In addition, manufacturers can run collision simulations specifically for hazardous cargo scenarios, as well as emergencies occurring during vehicle failure. By ensuring enhanced simulation accuracy with the correct amount of data fed into the simulation models, the automotive industry can start improving global safety, a cornerstone of the modern automotive industry. Not to mention, enhancing safety in autonomous vehicle testing and during project runs, everyone who takes part in the testing benefits from the technology.
Reading suggestion: High-Quality Training Data for Autonomous Vehicles in 2023
Enabling Autonomous Vehicle Development
The development of autonomous vehicles encompasses a broad scope of technologies requiring extensive validation. Traffic scenarios are often unique and unsuitable for physical testing. AI algorithms can manage, albeit virtually, the vast amounts of simulations required for exhaustive validation. Virtual shortcuts provide meaningful orientation for further physical testing in test tracks or piloted cars. They also accelerate the validation process by filtering pertinent scenarios.
Offerings from the leading vendors in this sector encompass real-time simulation services and platforms, libraries of scenarios, data labeling mechanisms, and different tools to qualify the AI decisional stack models. These platforms are typically general, multi-industry simulations with top-notch capacity. It is then up to specialized companies to create a relevant set of simulated traffic scenarios.
Furthermore, Digital Twin providers also propose data collection and management platforms. Their data pipeline processes acquired data from physical testing scenarios to qualify the vehicle perception system. They also include scenarios from real-life driving, construction, and municipal data relevant to the validation set of scenarios.
ADAS scenario libraries have obvious business-for-a-given model potential. Traffic simulation platforms often use a business model for credits or subscriptions. In this scenario, the further the scale, the more profit there will be. Presently, data management platforms focusing on self-driving vehicle scenario management are specific to the customer’s existing data infrastructure. Their business model might encompass a one-time project or subscription. Their specialization is sometimes focused on the processing and annotation of specific data like raw sensor data or data from directed test drives while combining this with the customer’s simulated traffic scenarios. This is typically reflected in the business model.
Enhancing Supply Chain Management
Modern cars are highly complex, with higher proportions of electronic and software components all the time. In recent years, vehicles have stopped being simply cars or means of transport, and big manufacturers such as Ford, Volkswagen, and Nissan are turning into tech companies that create hardware and devices with autonomous driving features, connectivity, continuous updates, infotainment, car sharing, or user experience for their wide customer base. In this challenging context, the digital twin has become an enabler to achieving such a digital transformation in the automotive industry by offering accurate and predictive mirrored simulations of their products, manufacturing processes, and supply chains.
Vulnerabilities in the automotive value chain demand transparency in terms of security and resilience. With the help of a digital twin representation, possible risks can be identified and weighted within the surroundings of each directly involved member of the chain. Especially, complex supply chains can benefit from this type of digital overview. Place digital twins along the supply chain to enhance individual awareness of the entire relevant factors and benefit from joint security concepts, mitigating easy attack capabilities that arise due to non-cooperation between trusted partners. Therefore, cyber-physical attacks generally start with targeting industry suppliers as the weakest link within the supply chain. Different members must be considered and aware of these risks, in case some action is required.
Reading suggestion: Enhancing Safety Through Perception: The Role of Sensor Fusion in Autonomous Driving Training
Improving Energy Efficiency and Sustainability
For the last two centuries, the automotive has been a symbol of industrial development and changing society. Like many other industries, automotive is under the pressure of Industry 4.0 requirements (time compression, fast and flexible manufacturing, efficacy increase, etc.) and the needs of the environmental, social, and regulatory forces. These challenges often have an antagonistic nature. For example, reducing a vehicle’s weight improves energy efficiency but makes production more difficult. Energy efficiency and waste reduction are also important factors. Digital Twin has applications in all stages of the automotive life cycle and for all processes of this life cycle.
The goals of the automotive industry are quite diverse but can be formulated in the form of answering the following questions: how to convince a customer to buy vehicles produced, and how to produce these vehicles (car, bus, motorcycle, bicycle, tractor, earthmover machine, etc.) in a profitable, energetic, and sustainable way.
The customer acquisition question results in increasing the vehicle’s technology and diversification, profitability, safety, etc. The trading and production answer leads to the need for eco-friendly means and methods of promoting, for example, less polluting vehicles, intermodal transportation, urban light electric vehicles, critical materials substitution, remanufacturing, etc. Therefore, Digital Twin with its combinations of smart, electric, digital, material, and ecology tools is a proper methodology for solving these tasks.
Enhancing Customer Experience and Personalization
With centralized and accessible data on the vehicles in the field, it is possible to personalize services and customer experience. A clear characteristic is the prediction and rectification of failures before the user is affected. With the aid of supervised learning combined with the fault tree analysis technique, it is possible to build models to predict which parts and/or systems will fail, and, based on the data of the vehicle and the location of these components, it can guide the next maintenance of the car. It is as if the brand is suggesting taking the car to the concessionaire to avoid a possible problem. Of course, with this same tool, it is possible to make more general reports. For example, suggest places to which the customer can take their vehicles for detailing, new tires, a part that must be updated, among others.
Conclusion
As digitization continues to unlock opportunities across industries, there has been a marked interest in digital twin solutions, and the automotive industry has been no exception. From products to production, digital twin technology has the potential to bring foresight and insight to companies, that are taking steps to embrace innovative digital twin technologies to thrive in competitive markets.
At Digital Divide Data we stand at the forefront of technology and we strategically integrate digital twin simulations while training autonomous driving data sets. You can learn more about our autonomous driving solutions or talk to our experts at DDD.
