Executable Digital Twin for Industrial Dispensing Systems

In high-precision dispensing systems, the very process parameters that are crucial are often difficult to measure directly—such as the actual mixing quality or internal material conditions. At the same time, the calibration effort is significant: Using a conventional approach, calibrating a single web requires about 50 measurements, which can amount to roughly one workday.

In this technical presentation, Olgierd Zaleski demonstrates how to set up and use a physics-based 1D model in Simcenter Amesim as the foundation for a functional digital twin.

• Modeling the actual dispensing system (tanks, pumps, pipes, mixers, nozzle) as a 1D system model in Amesim

• Material Modeling of Non-Newtonian Fluids Based on Rheological Measurements (Herschel–Bulkley Approach)

• Development of an Abstract Mixer Model and Calibration Using Measurement Data

• Preparing the Amesim model for export as a real-time-capable Functional Mockup Unit (FMU)

• The model's role as a "virtual sensor" for variables that cannot be measured using conventional sensor technology

An example from the presentation: With the new solution, the calibration of a track—which would otherwise take an entire day—could be reduced to about 15 minutes in some cases.

This presentation is intended for teams that want to use Amesim for targeted system simulation to better understand and monitor real-world dispensing processes and develop them into functional digital twins.

Technical presentation available as a video download: