Development of a Digital Twin for a Multi-axis Vibration Testing Setup

Dynamic environmental tests play a crucial role in verifying that components will perform as expected in operational conditions. Multi-axial testing platforms have continuously grown in popularity because they are capable of more accurately replicating the in-service environment than traditional single-axis vibration control tests. In a digital twin (DT)-based approach, correlated/validated numerical models of both test rig (including shakers, fixtures, etc.) and device under test (DUT) can be coupled to encapsulate the complex dynamic interactions between test hardware and article. This DT of the testing platform can become a powerful tool for the design and preparation of multiple-input multiple-output (MIMO) test configurations and provide a virtual environment for pre-test analysis of the multi-axis vibration test, predicting the expected test results in advance. Consequently, the test engineer can optimize the campaign beforehand and ensure the integrity of the DUT. This paper describes a model-based framework used for the development of a virtual simulation environment of a vibration test rig. The latter is based on a 4-degree-of-freedom multi-axis shaker platform combining four commercial medium-sized electromagnetic exciters in a decoupled build. The resultant DT combines electromechanical shaker models and a reduced order model (ROM) of the multi-axis platform. Finally, the virtual responses from the digital twin of the multi-axis platform are validated against experimental data, and its potential application to perform highly accurate pre-test activities is discussed.