KU Leuven leverages AR and Digital Twins for gearbox dynamics advancements

The essence

Predicting and preventing equipment failures in complex mechanical systems remains a challenge. At KU Leuven, traditional methods involved complex data analysis, creating a gap between research and real-time application. They had also discovered that vibration analysis, though essential, often yielded complex graphs and figures that are hard for a wider audience to understand. Mr. Watts teamed up with them to leverage the power of AR and digital twins, revolutionizing predictive maintenance while providing easy-to-understand, real-time visualizations.

Two-part challenge

We initially connected with KU Leuven a few years ago, but it wasn’t until recently that our collaboration began to take shape. Bert Pluymers, overseeing various activities within the KU Leuven LMSD division focused on mechanical and mechatronic system dynamics, identified two primary aspects of the challenge at hand.

“First, the heavy dependence on post-test gearbox data analysis made it difficult to interpret data and lacked the real-time aspect needed for practical use”, Bert says. “Additionally, the resulting graphs and figures were not accessible to the general public and industry stakeholders. Driven by Nerdland’s growing influence and the rise of citizen science, we knew it was time to tackle this challenge head-on.”

(Digital T)win-win

Mr. Watts got straight to work! Using the HoloLens 2, we created a visualization that overlays a heatmap directly onto the gearbox. This spatial alignment allowed us to visualize various parameters, including strain and displacement, on the gearbox’s outer casing – the shell.

“The heatmap displays a color spectrum from blue to red, helping viewers understand what’s happening in real-time, as if they had X-ray vision for the gearbox”, Bert explains. “Before our solution, people could only measure the parameters and view them as graphs and numbers. Now, they can observe the gearbox’s behavior live by adjusting the rotation speed or applying more force.

“By combining the power of AR with digital twins, Mr. Watts effectively transformed the way gearbox operational data is visualized and understood”, Bert confirms.

Breakthrough on many levels

The success of this innovative solution is currently being showcased at open days and events, allowing both technical and non-technical audiences to witness the technology’s potential and applications firsthand.

“By showcasing a real-world application of AR and digital twins in the manufacturing industry, Mr. Watts paved the way for improved maintenance and efficiency. I think their approach will definitely inspire other industries to follow suit”, Bert concludes.