Hierarchical Modeling for an Industrial Implementation of a Digital Twin for Electrical Drives

Digital twins have become popular for their ability to monitor and optimize a process or a machine, ideally through its complete life cycle using simulations and sensor data. In this paper, we focus on the challenge of accurate and real-time simulations for digital twins in the context of electrical machines. To build such a digital twin involves not only computational models for the electromagnetic aspects, but also mechanical and thermal effects need to be taken into account. We address mathematical tools that can be employed to carry out the required simulations based on physical laws as well as surrogate or data-driven models. One of those tools is a model hierarchy of very fine to very coarse models as well as reduced order models for obtaining real-time simulations. The required software tools to carry out simulations in the digital twin are also discussed. The simulation models are implemented in a pipeline that allows for the automatic modeling of new machines and the automatic configuration of new digital twins. Finally, the overall implemented digital twin is tested and implemented in a physical demonstrator.