Hybrid digital twin and AI soft sensors for optimized manufacturing
This innovative solution integrates a physics-based digital twin with AI soft sensors to enhance manufacturing processes. It provides real-time guidance, optimizes energy and water usage, and ensures consistent product quality across sites.
Overview
The Hybrid Digital Twin and AI Soft Sensors solution is designed to revolutionize manufacturing processes by combining advanced simulation technology with artificial intelligence. By leveraging a physics-based digital twin, this system simulates manufacturing operations such as mixing, heating, extrusion, and drying. When paired with AI-driven soft sensors, it allows manufacturers to conduct extensive 'what if' scenarios, optimizing for efficiency and quality. The system provides real-time, operator-facing guidance through an OPC UA/API interface, improving first-time right production capabilities and enabling cross-site benchmarking.
Technical specifications
- Digital Twin Technology: Integrates mechanistic models calibrated with plant data for high-fidelity simulation of manufacturing processes.
- AI Soft Sensors: Employs a Bayesian optimized multivariate Gaussian process (MVGP) stack for accurate prediction of product traits and detection of process drifts.
- Real-Time Guidance: Uses GLR logic and AI to recommend process set points, optimizing energy and water consumption.
- Deployment: Operator-facing guidance is delivered via OPC UA/API, facilitating seamless integration into existing systems.
- Validation Phases: Includes multiple phases from building and calibrating models to pilot testing and full deployment, ensuring robust performance and scalability.
Technology readiness level
This technology has reached Technology Readiness Level 6, indicating that it has been validated in relevant environments and is ready for further pilot testing and deployment. The solution has demonstrated sub-10% model error and significant energy and throughput gains, paving the way for streamlined manufacturing operations.
About Re-Du Company
RE-DU is a recycling technology company that has developed a patented process for the chemical deconstruction of mixed plastic waste. By breaking down diverse plastic types—such as PET, PC, PU, and PA—into monomers, the company enables the transformation of previously difficult-to-recycle materials into commercially valuable chemical products. This technology eliminates the need for costly sorting of mixed waste streams and offers an efficient, cost-effective alternative to traditional plastic management systems, which often rely on outdated processes that fail to address the majority of global plastic waste.
By providing a scalable solution for chemical recycling, RE-DU aims to reduce reliance on fossil fuels and minimize the environmental impact of plastic pollution in landfills. The company serves as a partner for industries seeking sustainable chemical feedstocks and is contributing to the development of a circular economy. Supported by initiatives like the Innovation Crossroads Award and research collaboration with Oak Ridge National Laboratory, RE-DU is positioned to help transition toward a net-zero carbon society by proving that mixed plastic waste can be successfully converted into high-quality, reusable resources.
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