Abstract
Prognostic and health management technologies are increasingly important in many fields where reducing maintenance costs is critical. Non-destructive testing techniques and the Internet of Things (IoT) can help create accurate, two-sided digital models of specific monitored objects, enabling predictive analysis and avoiding risky situations. This study focuses on a particular application: monitoring an endodontic file during operation to develop a strategy to prevent breakage. To this end, the authors propose an innovative, non-invasive technique for early fault detection based on digital twins and infrared thermography measurements. They developed a digital twin of a NiTi alloy endodontic file that receives measurement data from the real world and generates the expected thermal map of the object under working conditions. By comparing this virtual image with the real one acquired by an IR camera, the authors were able to identify an anomalous trend and avoid breakage. The technique was calibrated and validated using both a professional IR camera and an innovative low-cost IR scanner previously developed by the authors. By using both devices, they could identify a critical condition at least 11 s before the file broke.