Digital Twins


The concept of digital twins is as brilliant as it is simple. Wherever there is an actual, physical helicopter system that reports performance data on an ongoing basis, there can be a virtual twin existing in cyberspace. As the physical system clocks up hours and transmits performance data in real-time, that data can be input into the virtual model. The result is an AI-enabled digital twin that can be used to predict faults, test performance limits, and try out possible repairs, all without having to take the physical system out of service.


This is why helicopter OEMs such as Sikorsky are using digital twins in their MRO businesses. “Digital twins bridge the gap between the physical and digital world and help our customers make informed sustainment planning decisions,” said Halvorsen. “By incorporating the digital twin into our customers’ infrastructure, we can identify spare parts needed ahead of mission completion.”


Sikorsky’s first fully digitally designed aircraft was the CH-53K, which uses digital twins to enhance its maintenance and systems monitoring. “We are also developing next-generation digital twins for our Future Vertical Lift offerings,” Halvorsen said. “We recognize that to remain competitive we must explore ways to make things quicker, more efficient, and cost effective. For our legacy aircraft, we have also teamed with the U.S. Army and NIAR to convert our legacy UH-60L data into a digital twin.”


A UH-60L Black Hawk helicopter is prepared for shipment at Corpus Christi Army Depot for an 800-mile journey to Wichita State University where researchers at the National Institute of Aviation Research (NIAR) will create a virtual model of the work horse of Army aviation.


Photo: Lisa Simunaci


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Jan/Feb 2022


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