Digital Twin Evidence Pack

Start with Cynergy Blue’s Digital Twin Evidence Pack: a focused Phase 1 that delivers a calibrated, decision-ready digital twin and the integration artefacts your CEO/CTO/CFO expect—so you can make a defensible go/no-go in weeks, with minimal internal load and no disruption to ongoing programs.

What is a digital twin?

A holistic digital representation of your future uDrive-powered product—parameterised to your requirements (target kW, duty cycle, environment, interfaces, integration mode)—that runs real-world simulations and detailed analyses. Deliverables include decision-grade outputs (τ–θ loops, ∮τ dθ, efficiency maps), envelope & renderings, and interface specifications ICD^[1], telemetry, safety), enabling engineering, finance, and operations to make a defensible go/no-go for an internally built prototype—before anyone cuts metal.

What we provide

• Digital-twin stack for non-linear mechanics: MFBD^[2] with rigid–flex bodies, contact/friction, spring pre-load, phase-timed actuation; co-simulation with controls; FMU export for HIL/EMS prototyping. The twin reproduces τ–θ, ∮τ dθ (cycle energy), and stability under duty cycles.
• Bottom-up, evidence-first workflow: Model → Simulation → Prototype → synchronised metrology → feedback with clear KPIs (efficiency, stability, reproducibility) and formal reports.
• Complete skills spine: CAE/MBD, CAD/CAM & DfM, coatings/tribology, precision prototyping, DAQ/real-time controls, data engineering, quality/safety. Core capabilities in-house; external application engineers as needed to keep velocity high.
  

Why this matters

• Speed & cost: Board-grade evidence in 10–12 weeks—without diverting specialist staff or disrupting existing programs.
• Quality of evidence: Board-grade, traceable metrics—τ–θ agreement, ∮τ dθ (cycle energy), and efficiency maps vs. stiffness/backlash—tied to your requirements, not opinions.
• Organisational fit: Tool-agnostic artefacts you keep (incl. optional FMU^[3]).
  

What’s inside the Pack (deliverables)

• Twin-0 / Twin-1 model: Non-linear contact & friction, spring pre-load, phase-timed actuation; selective rigid–flexwhere compliance matters.
• Calibration & correlation: Parameter ID to match ⟨τ⟩ and ∮τ dθ at agreed points; uncertainty bands and a V&V note (assumptions, error bars, sensitivity coverage).
• Performance map: Efficiency windows vs. rigidity/backlash; phase-timing sweet spots; operating envelope (speed, load, thermal).
• DoE^[4] summary: Which tolerances, surface finishes/coatings, and controller timings move the needle—and by how much.
• Industrial renderings & key engineering data: Cabinet visuals (target kW class), envelope & mass estimates, mounting, service clearances; early torque–speed curve, bearing L10 estimate, lubrication/tribology assumptions.
  

How it runs

• Requirements & Interfaces: Requirements workshop → ICD + RTM; lock test protocols (baseline, symmetry-null, asymmetry window, rigidity sweep).
• Modelling & Calibration: Build Twin-0 (match τ–θ & ∮τ dθ), add selective flexibility → Twin-1; run targeted DoE.
• Evidence Pack hand-off: Model, maps, renderings, ICD, V&V, optional FMU; one-page KPI summary + technical appendix (raw data & scripts).
  

Roles

• Our team (design authority): Modelling, parameter ID, DoE, Verification & Validation, integration artefacts, Phase 2 test protocols.
• Your team (manufacturing owner in Phase 2): You manufacture & assemble the prototype under your QMS (FAT/SAT using our procedures). We supply Manufacturing Package Rev A (CAD, GD&T, BoM, coatings/lubricants, assembly & instrumentation plans) and first-build support.