Conceptional Design of a Digital Twin to Predict the Useful Lifetime of a Gearbox

In figure 1 the schematic approach of this thesis is summarized. The outcome can be categorized in four sections with similar extent. In the first section, "Service", the digital twin concept is elaborated on the basis of investigated requirements which are defined via the identification of the system stakeholder for the realization of MoL applications. The focus on service provision is enabled via the system-protagonist interaction analysis which is represented by the aggregation of use cases. The development procedure is accompanied by SysML diagrams which are part of the section "Representation". For the modeling of the interactions between the protagonists and the digital twin, sequence diagrams are created. The static system structure is represented by block diagrams which are generated in the software "Enterprise Architect". The third section, "Analysis", includes the related gearbox investigation which is summarized in a simulationmodel that is comprising besides a diagnostics part with load-based (damage accumulation) and vibration-based (IAS signal analysis) approaches, a prognostics part, which is presenting a similarity and degradation estimation. The data input to the simulationmodel is established by HCP-Sense bearings and magnetoresistive sensors which are applied for monitoring the gearbox components, namely the bearings and the gear wheels with their toothing. Based on the data input from the sensors the subsequent information transmission within the system structure is described in the fourth section, "Communication". In this section, interfaces which are categorized by OSI-layers and the specification of objects, transferred between the system elements, are defined. The modularity of the system structure is achieved by the definition of adaption nodes.