Simcenter Executable Digital Twin – The leap forward in digital twin technology 

The Dawn of a New Era

We are living in an era of unprecedented digitalization. Simulation and the digital twin have both proved their worth as key enablers of innovation, helping companies to:

• significantly reduce time and cost to market,
• improve product performance, and
• enhance sustainability.

According to McKinsey, almost 75% of companies have already adopted digital twin technologies.

But why the executable digital twin?

For decades, simulation has increasingly become a cornerstone of product development programs. Simulation models now contain a wealth of information and know-how that has been built over decades of product iterations and updates. Traditionally, simulation and the knowledge it provides have only been available to design and engineering teams while manufacturing and operation teams typically need to rely on approximate data.

What if every step of the development process from design and engineering, to R&D, to manufacturing and operations, and even to machine service departments, could take advantage of the plethora of knowledge contained inside these simulation models? Enter the executable digital twin. This technology makes digital twin models accessible for anyone in your company, at any point of the product lifecycle. Executable models can be seamlessly integrated into operational systems and used for real-time analysis and control. This brings tremendous value to every step of the development process, and even during operations.

Siemens is excited to announce the release of Simcenter Executable Digital Twin, enabling you to deliver smart products and processes by connecting the real and physical worlds.

What is Simcenter Executable Digital Twin?

Simcenter Executable Digital Twin is an advanced solution that synergizes high-fidelity simulation models with real-time data and control algorithms. Unlike traditional digital twins, which primarily serve as passive models, the executable digital twin (xDT) can actively interact with its physical counterpart, providing dynamic insights and responses to changing conditions. It effectively combines the real and the digital worlds, opening up new possibilities for enhancing operational efficiency, reducing downtime, and improving overall performance.

It’s like supercharging your products with simulation. The physical measurements are fed to the xDT which augments these data with simulation, providing engineering insights about the product performance. In real time and for anyone in the product lifecycle.

Why it matters

Accelerate innovation by shifting left

Simcenter Executable Digital Twin accelerates innovation by enabling comprehensive model-based system testing, including the crucial capability to test hybrid systems and perform virtual commissioning. These hybrid systems, composed of both physical components and xDT representations of other parts of the system, allow for a unique and powerful testing approach.

The xDT can replicate the behavior of real-world counterparts, allowing engineers to integrate physical hardware with virtual models in a cohesive testing environment. This enables the evaluation of system interactions and performance under realistic conditions, even when all physical parts are not yet available or easily accessible. For example, a physical prototype of a critical subsystem can be tested in conjunction with xDT models of other interacting systems, allowing for early validation of integration, performance, and potential issues before the entire physical system is assembled.

Furthermore, the xDT facilitates virtual commissioning by allowing control software and automation logic to interact with the simulated parts of the hybrid system. This means that the control systems can be tested and validated in a safe and cost-effective virtual environment before they are deployed to the physical system. This reduces the risk of errors and costly rework during final commissioning, leading to faster deployment and increased confidence in the overall system’s performance and reliability. This combined approach of hybrid system testing and virtual commissioning significantly reduces development time and cost.

A lifetime value from digital twin models by shifting right

Simcenter Executable Digital Twin enables companies to extend the use of simulation models beyond design and engineering into manufacturing and operations. This shifting right allows companies to extend the use of digital twin models, effectively maximizing the ROI from simulation and creating a lifetime value.

Real time decision making

Simcenter Executable Digital Twin empowers real-time decision-making by providing deep insights into system behavior and enabling process optimization.  By continuously mirroring the physical system, the xDT generates a wealth of real-time data and actionable information. 

Through advanced analytics and visualization tools, the xDT allows users to understand complex system interactions, identify bottlenecks, and predict potential failures before they occur. This granular understanding of system behavior allows for informed, real-time adjustments to operating parameters, optimizing performance and preventing costly downtime. 

Furthermore, Simcenter Executable Digital Twin facilitates process optimization by enabling “what-if” scenarios to be explored in a virtual environment.  Operators can simulate the impact of different control strategies or process changes, allowing them to identify the most effective approaches for maximizing efficiency, minimizing waste, and improving overall productivity. 

By bridging the gap between the physical and digital worlds, Simcenter Executable Digital Twin provides the critical insights needed to make proactive, data-driven decisions that drive operational excellence.

Achieve operational excellence

Simcenter Executable Digital Twin is a key enabler of operational excellence, driving improvements in both reliability and sustainability. By providing a real-time, virtual representation of the physical asset, the xDT allows for proactive identification and mitigation of potential failures.

Predictive maintenance strategies, powered by the xDT’s insights into system behavior and performance, enable timely interventions, minimizing downtime and maximizing equipment lifespan. This translates directly into increased reliability and reduced maintenance costs.

Furthermore, the xDT plays a crucial role in enhancing sustainability. By optimizing processes and resource utilization, the xDT helps minimize energy consumption, reduce waste, and improve overall efficiency. Through simulations and analysis, operators can identify areas for improvement in resource allocation, optimize production schedules to minimize environmental impact, and explore alternative, more sustainable operating strategies.

Ultimately, Simcenter Executable Digital Twin empowers organizations to achieve operational excellence by creating a closed-loop feedback system that continuously improves reliability, reduces environmental footprint, and drives sustainable operations.

“With the calculations from Simcenter Executable Digital Twin, we can predict changes, analyze the current situation, and we can accordingly optimize the operations.”

Catherine Steukers, BASF

The Simcenter Executable Digital Twin solution

Model

A digital twin is a virtual model of a physical system that predicts real behavior. Simcenter provides tools for building these models across domains, enhancing predictive capabilities.

Package

The Simcenter authoring tools enable users to package the digital twin in a self-contained asset, also known as the xDT instance. These Simcenter authoring tools and their capabilities are available across the Simcenter portfolio, and they enable the creation and export of xDT instances. These capabilities enable users to deal with different models and use different technologies. From AI and ML to physics-based ROMs to full fidelity system simulations, users can select the most suitable solution to solve their challenges. Furthermore, xDTs use industry standards such as FMI (Functional Mock-up Interface), ONNX (Open Neural Network Exchange) and more to maximize compatibility. 

Deploy

The xDT connects to live physical systems, dynamically linking virtual and real assets. Powered by the vast array of Siemens hardware, software and services, it paves the way for new levels of innovation.

Simcenter Executable Digital Twin supports multiple platforms for Model Based System Testing, Edge Computing and Cloud computing. With the introduction of the Simcenter Executable Digital Twin Gateway application, the deployment and management of xDT instances becomes extremely easy and scalable. With just few clicks you can activate new xDT instances and retire old ones. All done through an intuitive and simple to use interface. This allows users to minimize the IT complexity during deployment.

Operate

Combining the real and digital worlds, Simcenter Executable Digital Twin makes engineering insights available beyond design. This unlocks new opportunities that empower real-time adaptation and enhance productivity. The possibilities are countless and there is value for any industry or application. Virtual sensing, performance optimization, diagnosis and predictive maintenance are just some examples.

Getting Started with Simcenter Executable Digital Twin

Deploying simulation models in operations has never been so easy. The Simcenter portfolio provides all you need to package and deploy your xDTs. With just a few clicks, you are ready to leverage your best simulations as part of your physical product, effectively connecting the real and digital worlds.