Navigating automakers to futuristic revolution
“The global digital twins in automotive market size was valued at $2.2 billion in 2022, and is projected to reach $34.6 billion by 2032, growing at a CAGR of 32.6% from 2023 to 2032.”
I’m not surprised by the prediction of Allied Market Research about the use of digital twins in the automotive industry. Here, I’ll take you through the recent developments in automotive manufacturing after the adoption of ‘digital twins’ and how they revolutionize the jobs of automakers.
Porsche Taycan, the luxury car from Volkswagen Group, has the ultimate comfort and driving pleasure, thanks to ‘digital chassis twin’ testing of air suspension based on digital twins technology to evaluate the in-vehicle experience. Without going for actual product testing, it gives data-driven analysis, real-world performance, and service diagnostics. It also works collaboratively with ‘Advanced driver-assistance systems (ADAS)’ and automated driving (AD) platforms to share data to learn and identify customers’ driving styles and design self-driving models according to the usual routes.
According to Porsche media, “The digital chassis is already being used for its first practical testing scenario: monitoring the components in the air suspension of the Porsche Taycan. This project is primarily for collecting data about body acceleration in this initial stage. The data is evaluated and transferred via Porsche Connect to the central backend system. This system continuously compares the data from each vehicle against the fleet data. The algorithm calculates thresholds based on this comparison and, if these are exceeded, the customer is notified via the onboard Porsche Communication Management system (PCM) that the chassis may need to be inspected at a Porsche Centre. While this approach ensures that wear does not got beyond specified limits, early repairs also help to prevent consequential damage.”
Digital Twins for automotive
The digital twins for the automotive industry is the precise and accurate virtual model of a vehicle, component, or production plant to display their development throughout the entire lifecycle or procedure to predict, review, and analyze its performance, design, and production experiences and behavior. Without going for actual production or development, this digital replica or prototype helps automakers get testing done in similar conditions to get insights and data to understand the impact and experience to make further improvements.
Digital Twins revolutionizes automotive manufacturing
Video courtesy: Renault Digital Twins Car
What would tomorrow’s automotive designs and performance testing look like? Any ideas! You’ll be excited to know that the future of car designs, testing, and performance for evolving customer demands and the ever-evolving landscape of the automotive industry is in the digital realm with the help of ‘Digital Twins.’
Here are some of the most interesting and innovative uses of this trending technology in the automotive world, which fuses concepts into digital prototypes to turn them into reality.
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Vehicle design and testing
Businesses around the globe are spending huge to conceptualize, design, and test vehicles or components to obtain performance data to evaluate their quality performance to further improve it. With a digital twin, you don’t need to go for real car testing and performance data — like in the above Renault virtual car modeling that stimulates everything, including bodywork, chassis, circuitry and electronics, engine, tires, and even a virtual occupant to test human-like experience in different conditions for engine performance, gear management, bodywork aerodynamics, and even car air conditioning (AC) efficiency. Using these 3-dimensional digital simulation tools, the car designer and engineer can easily assess positioning (ergonomics), HMI (human-machine interface), Advanced Driving Assistance Systems (ADAS), and more. Automakers now preview and analyze the car’s performance and bring changes for better quality, performance, safety, and comfort before the car is built and leaves the factory to the showroom.
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Increase manufacturing capacity
The digital and physical system accelerates the manufacturing capacity of the assembly line for any automotive unit. Introducing a new product is one of the most ambitious goals for automakers, but it interrupts the existing assembly schedule. Digital twins come to your rescue before you put your money into equipment and components manufacturing.
With digital twins technology, automakers cannot only stimulate production capacity and review its impact on the production schedule, but also test equipment and components virtually. This allows for thorough testing before physical installation in the vehicle, mitigating the risk of errors and disruptions.
Mercedes-Benz, the luxury automotive brand is the perfect example here that utilizes digital twins to virtually increase its existing assembly line with minimal disruption. At the Mercedes-Benz plant in Rastatt, Germany, they introduced the ‘Digital First’ approach by the Mercedes Modular Architecture (MMA) model to save time, avoid defects, and enhance efficiency with real-time data to bring improvement.
“Mercedes-Benz ensures that the new production line for new models on the MMA platform in the existing Rastatt plant can be modified, configured and optimized using high-precision digital simulation techniques. The exact position of machines, supply routes and production lines can be determined and simulated in advance without interrupting the production of the current compact cars A- and B-Class, GLA and EQA,” as mentioned by Mercedes-Benz officials.
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Predictive maintenance
Maintenance and downtime are common concerns for automakers, car owners, and insurance companies to prepare beforehand before the actual occurrence. The maintenance schedule is a transformative decision that requires a 360-degree overview of operational insights and the driver’s driving style. A digital twin of a vehicle with a virtual driver helps to gain exact insights about real-world performance, parts life, and asset maintenance requirements so automakers can provide predictive maintenance routines easily.
Research by Deloitte has found that predictive maintenance improves equipment uptime by up to 20% and minimizes maintenance costs by 5 to 10%. We have Rolls-Royce, a multinational aerospace, car, and defense company that uses digital twins to improve jet engine efficiency and extend routine maintenance time by up to 50%.
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Plant infrastructure management
Moving further with the role of the digital twins in revolutionizing automotive manufacturing, we have plant infrastructure management. With a digital twin of your manufacturing plant, virtual reality, and connected applications, automakers can monitor them without physically being present there. Engineers can train workers remotely using a digital simulation of any equipment from any remote location. GM Motors has also introduced a digital twins-based Virtual Factory Testbed that mimics plant-floor behavior to support the concept of build-to-order manufacturing.
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Targeted recall
Digital twins empower automakers to target recall to impacted or defective products or components rather than recalling thousands of them. Automotive manufacturing units get full traceability to track key components and respective serial numbers in a digital twin that goes into specific products and keeps the recall minimal and more accurate. It improves productivity and helps automakers to become cost efficient.
With these impactful roles in automotive manufacturing, the digital twins brings unlimited simulation, continuous improvement, supply chain management, improved human factors, agility, aftermarket service, global collaboration, IIoT integration, production data manufacturing, training, and more. In the future, there will be more that automotive manufacturing can do with digital twins.
Final words
“The digital twin market valuation is estimated to cross USD 90 billion by 2032, as reported in a research study by Global Market Insights Inc.”
The above prediction confirms that ‘Digital Twins’ are here to stay and will drive the industries for the future of product design, production, performance, and, of course, innovation. It is fair to say that ‘digital twins’ are gradually replicating their success in various aspects of different industries. The automotive industry is one of the top early adopters of digital twins to transform their performance and experience.
Well, this is the tip of the iceberg; you must be interested in learning about and discussing the digital twins for the automotive industry manufacturing, so stay tuned. At Krish, our consulting experts help automotive brands harness technologies to their experience journeys. So, next time when you comfortably drive in your Taycan, remember the credit goes to the digital twins.
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Digital transformation expert and trusted advisor to global brands. With a career dedicated to navigating tech's evolution, she's led successful initiatives, driving businesses into the ecommerce future. Beyond the boardroom, she finds solace in mountain retreats, cherishing moments of inspiration with a bowl of Maggi. Whether crafting strategies or exploring new heights, Shruti's journey exemplifies innovation, resilience, and a zest for life's adventures.
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