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Related Concept Videos

Typical Model Studies01:30

Typical Model Studies

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Fluid mechanics model studies often utilize scaled-down systems to predict fluid behavior in full-scale environments, such as river flows, dam spillways, and structures interacting with open surfaces. Maintaining Froude number similarity in river models is crucial, as it replicates surface flow features like wave patterns and velocities.
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Modeling and Similitude01:12

Modeling and Similitude

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Scaled modeling is a fundamental technique in engineering, enabling the study of large and complex systems by creating smaller, manageable replicas that recreate critical characteristics of the original. In hydrology and civil infrastructure, for example, scaled models of dams help analyze water flow, turbulence, and pressure. This method allows for accurate predictions of real-world behavior within a controlled environment, significantly reducing the cost and time involved in full-scale...
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Design Example: Creating a Hydraulic Model of a Dam Spillway01:21

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Scaled hydraulic models of dam spillways provide a practical way to replicate and study the intricate flow dynamics of these structures. Often built to a 1:15 ratio, these models allow for observing critical water behavior, such as velocity distribution, flow patterns, and energy dissipation.
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Updated: Jun 11, 2025

A Modeling and Simulation Method for Preliminary Design of an Electro-Variable Displacement Pump
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Development of a high-fidelity digital twin using the discrete element method for a continuous direct compression

Dalibor Jajcevic1, Johan Remmelgas1, Peter Toson1

  • 1Research Center Pharmaceutical Engineering GmbH, Graz, Austria.

International Journal of Pharmaceutics
|October 4, 2024
PubMed
Summary
This summary is machine-generated.

A high-fidelity digital twin for direct compression drug manufacturing was created. This tool accurately predicts process outcomes using material characterization, aiding control strategy development.

Keywords:
Continuous manufacturingControl strategyDEM calibrationDEM simulationDigital twinResidence time distribution

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Area of Science:

  • Pharmaceutical Engineering
  • Computational Fluid Dynamics
  • Materials Science

Background:

  • Direct compression is a key process in pharmaceutical manufacturing.
  • Developing robust control strategies requires accurate process simulation.
  • Digital twins offer a powerful platform for virtual testing and optimization.

Purpose of the Study:

  • To develop a high-fidelity digital twin for direct compression drug product manufacturing.
  • To validate the digital twin's predictive capabilities using experimental data.
  • To establish a calibration method for Discrete Element Method (DEM) models in pharmaceutical processes.

Main Methods:

  • Development of a digital twin platform simulating pharmaceutical equipment and direct compression processes.
  • Detailed material characterization using bulk density, compression, shear cell, and rotating drum tests.
  • Application and calibration of a cohesive DEM contact model using experimental data.
  • Comparison of simulated system response with experimental results for API concentration changes.

Main Results:

  • The calibration method successfully differentiated between material batches with varying flowability.
  • Small-scale material characterization tests accurately predicted residence time distribution in continuous manufacturing.
  • The digital twin demonstrated sensitivity to DEM contact parameters, impacting process prediction.

Conclusions:

  • A validated high-fidelity digital twin can effectively support the design and testing of control strategies for direct compression manufacturing.
  • The proposed calibration approach enables accurate prediction of process behavior using fundamental material properties.
  • This methodology facilitates enhanced understanding and optimization of continuous pharmaceutical manufacturing processes.