Analysis of the framework and key technologies of solid rocket motor digital twin system

Solid rocket motor (SRM) digital twin technology enables comprehensive digital and intelligent management of the motor by creating a high-fidelity digital model of the actual SRM. This technology can be applied throughout the engine’s lifecycle to optimize design and maintenance through real-time monitoring, accurate prediction, and data-driven approaches. This not only significantly reduces R&D and maintenance costs, but also shortens development cycles and improves engine reliability and safety. Digital twin technology can integrate various types of data and overcome challenges that exist in traditional design and experimentation, such as the separation of design and experimentation and the under-utilization of data. With this technology, SRMs can be managed more efficiently and accurately at all stages of design, manufacturing, testing, use and decommissioning. This comprehensive management model, combined with advanced information technology, can greatly promote the development and application of SRMs.

At present, the application of digital twins in aero engines has achieved initial results. the United States, Russia, France and other countries have actually applied digital twin technology to the production of aero engines. For example, Russia’s United Engine Company (UEC) has established engine digital twins to achieve comprehensive monitoring of the entire test process and improve the efficiency of problem finding and troubleshooting. China has also begun to study the application of digital twins in the aerospace field, such as the prediction of the remaining life of the aero engine turbine disk driven by digital twins proposed by Fu Yang, and the intelligent inspection and maintenance strategy of aircraft skin cracks based on digital twins proposed by Zhao Fubin. However, at present, the domestic research on SRM digital twins is still in the conceptual stage, and there are no publicly available mature cases.

This paper discusses the concept and development history of digital twins, studies the evolutionary process of the twin system for SRMs, divides it into four stages: physical twin, computer aided design/simulation, virtual reflection of reality, and combination of virtual and reality, and summarizes the system framework and key technologies for each stage. The application of digital twin technology to solid engine R&D will bring about a change in the SRM R&D and management mode, which will greatly reduce the R&D cycle and cost while giving the engine the ability of environment sensing, autonomous assessment, and autonomous decision-making.