Digital twin–based testing process management for large and complex equipment components

Digital twin (DT) is a key enabling technology to realize cyber-physical system (CPS), which can truly perceive, map, and predict the operating state of physical entity. Through analyzing the generality of the testing process of large and complex equipment components (LCEC), a five-dimensional framework of DT-based test process management (DTTPM) is proposed, which comprises physical layer, network layer, data layer, model layer, and service layer. In order to realize the visualization and enhance the controllability, security, and information transparency of LCEC in the testing process, three key technologies are elaborated in detail as follows: (1) the construction of the twin semantic model of the testing process in model layer, (2) the synchronization method of twin model and physical entity based on real-time data, (3) and human–computer interaction–based visual monitoring of authenticity and safety coordination. Through the case of the vibration test for the crowned blade of a steam turbine by blade tip-timing measurement, the feasibility and flexibility of DTTPM are demonstrated.