Scientists Utilize Digital Twins for Experiments

Engineers leverage advanced models to monitor operations, plan fixes, and troubleshoot problems.

In January 2022, NASA’s $10 billion James Webb Space Telescope (JWST) neared the end of its one-million-mile journey from Earth. This complex mission required the spacecraft to unfold through a precise sequence, a process fraught with 344 potential failure points. The telescope’s sunshield, as large as a tennis court, needed to deploy flawlessly, and its secondary mirror had to position itself perfectly on three legs, nearly 25 feet from the primary mirror. The primary mirror itself had to assemble its 18 hexagonal pieces in a honeycomb formation.

“That was a scary time,” recounts Karen Casey, a technical director at Raytheon, which developed the software controlling JWST’s movements. Throughout this sequence, Raytheon engineers relied on a “digital twin” of the telescope—a high-fidelity 3D model updated in real time with data from the actual telescope. This allowed them to monitor the unfolding process closely, akin to watching a suspenseful movie.

The digital twin concept, which creates a virtual replica of a physical object based on real-time data, was transformative for JWST. It allowed engineers to observe the telescope’s deployment and confirm that all 344 failure scenarios were avoided, ensuring the telescope reached its operational state. This high-tech monitoring continues to update, providing ongoing insights.

The idea of digital twins isn’t new to Raytheon, which has extensive experience in defense and intelligence sectors. However, JWST’s complexity pushed the technology further, setting a new standard for both space and defense applications. Dan Isaacs, chief technology officer for the Digital Twin Consortium, highlights that space is a unique intersection where defense and non-defense technologies converge.

800 Million Data Points

The digital twin concept originated in 2002 with Michael Grieves, who suggested that products should have digital counterparts constantly updated with real-world information. The term “digital twin” was later coined by NASA’s John Vickers in 2010. Technological advancements have since enhanced the capabilities of digital twins, integrating the Internet of Things (IoT), cloud computing, AI, and machine learning to handle vast amounts of data efficiently.

Raytheon’s digital twin of JWST tracks 800 million data points daily, converting this information into a real-time 3D video. This visualization helps engineers monitor the observatory and predict the outcomes of potential changes. By using an offline version of the twin, the team can test software updates, train operators, and troubleshoot anomalies.

Science, Defense, and Beyond

JWST’s digital twin is part of a broader trend where digital twins are used in various scientific and industrial applications. For instance, NASA’s Curiosity rover and CERN’s particle accelerators have their digital twins to assist with operations and maintenance. The European Space Agency is working towards creating a digital twin of Earth itself.

At the Gran Telescopio Canarias, engineers started developing a digital twin two years ago, integrating sensors to monitor environmental conditions and telescope operations. This system helps in managing the telescope more efficiently, and the team is now working towards an AI-enhanced version to predict and respond to changes automatically.

In the defense industry, digital twins are highly valued. The U.S. Space Force uses them to plan satellite refueling missions and simulate space environments to prepare for potential collisions. Such applications demonstrate the strategic importance of digital twins in both defense and scientific research.

Raytheon plans to leverage the JWST digital twin’s advancements across its defense projects, such as missile defense radars and aircraft systems. “We can reuse parts of it in other places,” says Casey, indicating the potential for widespread application of these innovations.

In summary, digital twins are revolutionizing how scientists and engineers operate complex systems, providing real-time insights and predictive capabilities that enhance performance and reliability. This technology’s impact spans from space exploration to defense, exemplifying the powerful synergy between advanced modeling and practical application.

MAIN PICTURE CREDITS: STEPHANIE ARNETT, VICHHIKA TEP/MIT TECHNOLOGY REVIEW | NASA