Mitsubishi Electric Corporation has announced the development of a new digital twin-based technology designed to correct machine-tool errors in real time on CNC-equipped systems. The innovation has been developed in collaboration with RWTH Aachen University.
The technology leverages digital twin capabilities to address machining inaccuracies caused by slight deformation of workpieces under cutting forces. According to test results, the system can reduce such errors by up to 50%.
By improving machining accuracy during the cutting process, the solution helps minimise defects, enhancing overall productivity. Additionally, the reduction in rejected parts contributes to lower material waste, supporting more sustainable manufacturing operations.
From April 2023 to March 2026, Mitsubishi Electric and RWTH Aachen University, which is renowned for its digital twin expertise, conducted joint research on online edge computing with a high-speed processing unit. As a result, they developed digital twin technology for CNC machine tools that can accurately estimate machining errors and feed the results back into the control system in real time. The digital twin’s proprietary compact physical model, which is composed of a minimum number of equations, was created using large amounts of data, including axis positions, currents and cutting forces. The data are acquired at a high sampling rate,3 and only information necessary for estimating machining errors is extracted. Real-time testing on a CNC machine tool confirmed that errors in machining due to a tool inadvertently deforming the part being cut can be reduced by up to 50%. By reducing defective parts and stabilizing surface quality, the technology improves productivity while reducing environmental impact.
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