DRDO Seeks Groundbreaking Digital Twin to Boost Aero Engine Performance Efficiency

Defence Research and Development Organisation Seeks Innovative Solution for Aero Engine Health Monitoring

In a bid to enhance the performance and reliability of India's indigenous aero engines, the Defence Research and Development Organisation (DRDO) has invited Indian companies, startups, and Micro, Small and Medium Enterprises (MSMEs) to develop a cutting-edge digital twin framework for Health and Usage Monitoring Systems (HUMS). This pioneering project aims to harness the power of physics-based modelling, artificial intelligence, and engine test data to monitor the performance of gas turbine engines and detect any abnormalities.

A Comprehensive Approach to Aero Engine Health Monitoring

The DRDO's Technology Development Fund (TDF) scheme is providing grant-in-aid support for the development of the digital twin framework, which will be designed to replicate the physical behaviour of the aero gas turbine engine in a virtual space. This will enable engineers to study the engine's subsystems, monitor operating parameters, and evaluate performance under different conditions.

Hybrid Modelling Approach

The project calls for a hybrid modelling approach, combining physics-based thermodynamic models with data-driven models developed using engine test results. This approach is expected to improve the accuracy of the virtual representation, enabling the digital twin to provide reliable and timely insights into the engine's performance.

Key Technologies and Features

Artificial intelligence-augmented thermodynamic modelling and virtual sensors have been identified as key technologies in the development of the digital twin framework. Virtual sensors will be used to derive or estimate parameters that cannot be measured directly, while sensor validation and recovery functions will help identify unreliable readings and support monitoring. The system is also expected to identify suitable sensor types, quantities, and locations for monitoring the engine throughout its service life.

Deliverables and Timeline

The tender calls for a comprehensive package that includes the hybrid digital twin, computing hardware, real-time operating capabilities, sensor validation and recovery systems, virtual sensor algorithms, a fault and alarm framework, and a graphical user interface. The interface will display warnings and alarms, present engine components visually, and support data storage and retrieval.

The development schedule extends across 30 months, with four principal milestones. The first six months will be devoted to requirements definition, architecture selection, and preliminary design review. By the 12-month mark, the development agency is expected to complete detailed design work, collect and preprocess data from 50 to 60 engine tests, and demonstrate an integrated engineering prototype incorporating 17 digital-twin blocks.

Safeguards for Sensitive Engine Information

The DRDO has specified safeguards for sensitive engine information, ensuring that experimental data is shared with the selected development agency for evaluation at DRDO-defined premises. Engine-run data will not be shared with the industrial partner outside those premises, and changes to the framework involving this data will be undertaken at DRDO facilities in consultation with its team.

Key Takeaways

• The DRDO has invited Indian companies, startups, and MSMEs to develop a digital twin framework for Health and Usage Monitoring Systems (HUMS) for aero gas turbine engines.
• The project aims to combine physics-based modelling, artificial intelligence, and engine test data to monitor gas turbine performance and detect abnormalities.
• The digital twin framework is expected to replicate the physical behaviour of the engine in a virtual space, enabling engineers to study the engine's subsystems, monitor operating parameters, and evaluate performance under different conditions.
• The project has a development schedule of 30 months, with four principal milestones, and includes safeguards for sensitive engine information.