Spot the Fault. Secure the System.

An HMI Redesign with 3D Digital Twin for Better Usability

Identifying errors before they become a risk

Reinhausen faced the challenge that technical faults in the GRIDCON® STATCOM system were difficult to identify. The existing user interface required extensive knowledge and training to pinpoint disruptions precisely. Additionally, affected system areas were not clearly recognizable as danger zones in the event of a fault.

To improve safety and simplify operation, we developed an intuitive interface that uses an advanced 3D model to visualize complex data and instantly locate the source of errors.

Client:

MR Maschinenfabrik Reinhausen

Energy Technology

Services:

UI Design

Prototyping

UX Research

UX Design

Project Management

Software Engineering

The Solution

With an innovative 3D digital twin solution, we completely reimagined the operation of MR's system from the ground up.

Project Results

In close collaboration with MR, we developed a consistent design system and an embeddable 3D model that makes complex KPIs intuitively accessible. Through a clear visual strategy – comprehensively documented in the client's Confluence – we were able to deliver the project exactly on schedule. The result is a high level of client satisfaction, already reinforced through a joint on-site system inspection, laying the foundation for a long-term strategic partnership.

Project Results

Launch and Inspire Workshop

We kicked off the project with a comprehensive workshop to develop a pioneering concept for fault identification. This involved close collaboration between our UX design, prototyping, and user research teams to gain a deeper understanding of the client's needs.

Design and Development of the 3D Digital Twin

During the implementation phase, we focused on designing and developing a 3D digital twin based on the client's CAD files. Particularly noteworthy is the versatility and genericity of the 3D component.

Unified 3D assets are generated from the existing CAD models, optimized for high-performance web rendering. The component is capable of displaying the 3D model directly and deriving relevant information – such as interactive areas or restricted system sections – immediately from the CAD data. This eliminates the need for manual post-processing or additional custom programming per system.

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Visual Language

The KPIs and the remaining interface were implemented by MR.To support this, we developed a comprehensive visual design including a component library, serving as the foundation for a consistent and unified visual language across the entire application.

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Integration and Support

The final implementation included integrating the new user interface into MR's existing system. Throughout this process, we guided the client through the code integration and flexibly adapted the interfaces as needed to ensure seamless embedding into the existing system landscape.

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Keeping the Full 3D Picture

The new 3D digital twin makes it possible to quickly identify faulty areas and take the necessary action. Access remains intuitive and the need for briefings is minimal. A comprehensive visual design and a unified component library significantly improve the usability and clarity of the new operator interface, while ensuring a consistent visual language.

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FiberQ Performance Dashboard

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Scalable & Low-Maintenance

The developed 3D component uses existing CAD data directly as the basis for visualization. Interactive areas and restricted system sections are automatically derived from the CAD model provided by the client, with no additional manual adjustments or custom programming required.Thanks to the standardized and reusable architecture, new machines or systems can be integrated with minimal implementation effort. The result is a scalable 3D solution that increases efficiency and significantly reduces maintenance overhead.

Improved Operational Safety

Through the implementation, we were also able to ensure that safety-relevant information is clearly visualized. Area restrictions and accessible zones are now displayed efficiently and reliably, significantly enhancing the overall safety of the system.