Digital twin "A knowledge base for data-driven decisions"

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With the PLM Portal@Bosch Rexroth, Bosch Rexroth consolidates all data of each product on a single platform: Using the digital twin technology of the Bosch Semantic Stack, a digital twin is created during product development, which accompanies the physical products throughout their entire life cycle. Uwe Haas from Bosch Rexroth explains the advantages of this.

Mr. Haas, how did the development of the "PLM Portal@Bosch Rexroth" come about?

The idea emerged when our development leaders discussed future topics and strategic objectives. We wanted to cover skills that go beyond pure change management in digital transformation. The PLM Portal is designed to help overcome the challenges of digitalization – especially introducing powerful digital product twins at Bosch Rexroth, which will secure competitiveness in the long run.

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How does the solution differ from conventional PLM systems?

PLM represents an approach to handling data throughout the entire product lifecycle. Experience has shown that a single tool cannot reflect this. Therefore, the PLM Portal is a “window into the world of data”. It is important here that access is made possible to data from different systems and information sources without the need to copy or store them separately. Thus, the domain-specific systems continue to serve their purpose and are linked together by the introduction of the PLM Portal.

So, does this mean that all data are continuously available?

Data is collected transparently and traceably across all phases of the product lifecycle, uniformly orchestrated, and made centrally accessible. The PLM Portal thus forms a digital platform for all product knowledge. Thanks to the unified access to information, not only product development benefits but also downstream domains benefit from the PLM Portal, such as service, which usually has to obtain information from various data sources.

When is the digital twin of the components created?

The digital product twin represents a digital representation of a physical product and reflects the different phases of the product lifecycle. Here, a distinction is made between a type twin and an instance twin. The type twin is created as soon as a first material number is available. It represents further information such as CAD models, bill of materials, simulation models, and customer specifications. The specific instance twin is created with the release of the manufacturing order and is the virtual representation of a product in operation, collecting all data from production through use to the end of the product life.

Does the solution offer advantages for product development?

In general, all departments can benefit from the fact that data and information are centrally accessible. This creates a so-called "single point of truth". The digital product twin enables the flow back of product usage data from the field. This allows the use of information from the instance twins (with the customer) to draw conclusions from the feedback and to identify potential improvements (in development).

What advantages does the PLM Portal offer your design departments, for example, in the development of drive technology components?

Our designers gain comprehensive insights into all products and components from Bosch Rexroth. This way, already generated knowledge is not lost, and designers can build on it. All collected data are structured in the PLM Portal and are easily accessible. For example, designers have access to models of existing components, which they can incorporate into the design of new products. This reuse of existing knowledge results in significant time and cost advantages. Additionally, the validation process is shortened by being able to use simulation models and test results. Furthermore, designers benefit from the engineering feedback of data generated in the field.

And how do designers and developers from Rexroth customers benefit?

The standardization of data and models offers a not to be underestimated advantage in cross-company collaboration. An important driver for this standardization is the Asset Administration Shell (AAS), which is developed and published by the IDTA. Bosch and Bosch Rexroth have been involved as active members from the beginning. The AAS provides the information package, for example, the simulation model, needed for the digital representation of products and the uniform exchange of information. This decreases manual efforts as well as coordination and communication – and significantly reduces integration effort.

Do you have an example ready?

An example is the product specification. During the pre-design phase, it allows the customer to make data-driven decisions on the configuration of, for example, drive technology or hydraulic components. For this purpose, information of the type twin such as documentation, CAD, and simulation models are provided in a standardized format to facilitate the overall process surrounding product selection.

Another example is virtual commissioning using simulations. This supports the development of preliminary designs, reduces subsequent iterations, and results in time savings. Thus, test runs of the entire machinery can be simulated and optimizations can be made before costly and expensive investments have been made.

Can the solution also be considered a knowledge management solution?

It is not a classic knowledge management solution. However, it covers certain areas of knowledge management, such as the collection of data and products from various information sources (usage, manufacturing, service orders, etc.), and provides a semantic description. Product knowledge is consistently depicted in the PLM Portal, always provides the current information, and is accessible with just a few clicks. Thus, the PLM Portal is a kind of knowledge cockpit and entry point for all employees, such as from customer service or design. Moreover, the collection of aggregated data from the digital product twins serves as a knowledge base for data-driven decisions.

How does Bosch's approach to digital twins differ from the solutions of the IDTA?

There is no difference. On the contrary, Bosch is an active member of the IDTA board, leads among others the "Open Technology" working group, and is heavily involved in the further development of the Administration Shell (AAS). We advocate for the use of open technologies. Therefore, we consistently rely on the IDTA standard. On this basis, we have developed highly scalable solutions that can process several hundred million digital twins.

Which products from Bosch Semantic Stack are behind it?

The PLM Portal is a Software-as-a-Service (SaaS) solution specifically developed for Bosch Rexroth. It includes the following components from the Bosch Semantic Stack portfolio: In the Digital Twin Registry, the control center for digital twins, all data from the various phases of the product life cycle converge. Aspect models describe the professional context and meaning of these related data, group them, and define the data structure specific to the domain. In order for the aspect models to be easily found and reused for new use cases, a digital library or central storage location is needed: the Aspect Model Catalog. Moreover, open-source components from the Eclipse Semantic Modeling Framework (ESMF) are used, such as an editor for aspect models. Bosch actively continues to develop these open-source components together with other companies.

Are the solutions from Bosch Semantic Stack also available externally?

Like all solutions from Bosch, the solutions from the Bosch Semantic Stack portfolio were first extensively tested internally and then rolled out externally. Currently, the Digital Twin Registry, the Aspect Model Catalog, and a comprehensive service offering for our customers are available.

Does the Digital Product Twin open up further opportunities for Rexroth for the future? Where can the journey go?

With the implementation of the digital product twin, Bosch Rexroth can further increase internal efficiency. Moreover, the twin is an essential basis for data-driven products and services, which could not be implemented without extensive structuring and collection of data.

Digital product twins play an important role in addressing current challenges in the context of sustainability, recycling, and the circular economy. The information provided by the twins is an important starting point for developing and establishing solutions for these challenges. For example, requirements regarding the traceability of products, such as the Digital Product Passport (DPP), can only be met based on this informational foundation.

And for your customers and users?

This diversity of use cases continues to open up the opportunity to develop new business models, such as the sale of simulation models and services to end customers and OEMs. Customers thus have the opportunity to simulate their machines and systems and carry out a virtual commissioning before making extensive investments in physical products. Through the Digital Service Assistant (DSA) app, customers already have round-the-clock access to their digital product twins. They can access all service tools and get an overview of the status of their products at any time.

Thank you for the interview, Mr. Haas!