Digital Twin
Digital Twin + physical testing
A Digital Twin increases the value of physical testing by helping engineers predict expected behaviour, compare measured results, investigate deviations and improve the next engineering baseline.
Physical ↔ digital
Build it.Model it.Test it.Correlate it.
Physical
Build Instrument Test Measure
Engineering correlation
Digital
Model Predict Compare Update
The twin loop
Predict. Test. Compare. Learn.
The loop runs once per test. Each pass leaves a prediction, a measurement and a decision on record.
- 01PredictBefore a test, the model says what the hardware should do in this configuration.
- 02TestThe instrumented hardware is tested to a written objective.
- 03CompareMeasured data is set against the prediction, and every deviation is investigated.
- 04LearnThe model, the hardware or both are updated — and the next test starts better informed.
The loop in detail
- Engineering model
- Prediction
- Physical test
- Measured data
- Predicted vs measured
- Engineering review
- Model update or hardware update
- Retest
What the twin does: pre-test prediction · simulation · expected response · scenario exploration · test planning · predicted vs measured comparison · anomaly investigation · model updating · design feedback.
Show values as a table
| Time | Predicted | Measured |
|---|---|---|
| 0.00 | 0.00 | 0.00 |
| 0.10 | 0.51 | 0.44 |
| 0.20 | 0.76 | 0.73 |
| 0.30 | 0.88 | 0.85 |
| 0.40 | 0.94 | 0.94 |
| 0.50 | 0.97 | 1.07 |
| 0.60 | 0.99 | 1.01 |
| 0.70 | 0.99 | 1.00 |
| 0.80 | 1.00 | 0.99 |
| 0.90 | 1.00 | 0.99 |
| 1.00 | 1.00 | 1.01 |
Digital Twin maturity
Five potential levels
Confidence in a twin is earned the same way as confidence in hardware: by evidence, within defined limits.
- Level 1ModelAn engineering representation of the hardware.
- Level 2Simulated systemSubsystem interactions represented.
- Level 3Correlated modelCompared with test measurements.
- Level 4Validated operating regionUseful agreement demonstrated within defined limits.
- Level 5Operational engineering twinContinuously updated where appropriate.
Configuration-aware twin
Same configuration, or no comparison.
Predicted-versus-measured comparisons are meaningful only when the digital and physical configurations correspond.
- Hardware baselinelinked
- Firmware baselinelinked
- Software baselinelinked
- Sensor packagelinked
- Calibration setlinked
- Test configurationlinked
- Model geometry baselinelinked
- Controller model versionlinked
- Sensor model maplinked
- Calibration importlinked
- Prediction setlinked
- Correlation reportlinked
Instrumentation
If you cannot measure it, you cannot correlate it.
- 01Pressure
- 02Temperature
- 03Force / thrust
- 04Vibration
- 05Strain
- 06Acceleration
- 07Rotational speed
- 08Position
- 09Timing
- 10Flow-related measurements
- 11Controller states
- 12Electrical measurements
Sensor to correlation — and who can contribute at each stage
- 01Sensor
- 02Signal conditioning
- 03DAQ
- 04Time synchronisation
- 05Test data
- 06Engineering analysis
- 07Digital Twin correlation
Engineering test data
Every test, a traceable record
Each physical test becomes a digital record tied to its configuration. Through the engineering collaboration, Gamyaa AeroSystems contributes digital-engineering, test-data, model-correlation and engineering-evidence capabilities.
- Test ID
- Test objective
- Procedure
- Hardware configuration
- Serial numbers
- Software version
- Firmware version
- Sensor configuration
- Calibration references
- Model revision
- Recorded data
- Events
- Observations
- Anomalies
- Analysis
- Disposition
- Approval