The Gateway from the Physical World to the Digital World: Digital Twin

Digital Twin applications are, at their simplest, applications that create a virtual copy of a physical product, process, or system. They act as a bridge between the physical and digital worlds by using sensors to collect real-time data about a physical object. This data is then used to create a digital replica of the item, enabling it to be understood, analyzed, manipulated, or optimized. Other terms used to describe technology over the years include virtual prototyping, hybrid twin technology, virtual twins, and digital asset management.

Digital Twin applications have increasingly been seen as a tool for the future since the rapid rise of Internet of Things (IoT) technology. They attract attention because they integrate data, algorithms, and context, allowing organizations to test new ideas, identify problems before they arise, and respond to innovations by using artificial intelligence (AI) and machine learning (ML).

Traditionally, Digital Twins have been used to improve the performance of individual entities like wind turbines or jet engines. However, with the impact of Industry 4.0, they have become more sophisticated in recent years. Now, they can model not only individual assets but also systems of assets and even entire value chains. As the ability to aggregate more assets and combine them with information about processes and people increases, so does their ability to help solve complex problems. The value they offer lies mainly at the organizational level in the built environment. They can be used to adopt a generally human-centered approach, then look at problems and context, and finally try to solve big problems and create long-term value by adding information systems and connected devices. For companies and organizations already using the concept of the Internet of Things in an up-to-date manner, Digital Twin projects come as the next step in the digital journey. Digital Twin projects can be initiated to increase efficiency, optimize processes, detect problems before they occur, and innovate for the future.

Digital Twin technology offers several fundamental benefits, as outlined below.

Accelerated Risk Assessment and Production Time

With Digital Twin technology, companies and organizations can test and verify the future of a system today. Digital Twin can be used to create a copy of production processes for production planning, matching orders with capacity or sequencing production orders, and even forecasting inventory needs.

Process Efficiency

Modeling processes within Digital Twin and testing them under all kinds of scenarios allow those responsible for the system to focus more on the nature of the system, thus increasing productivity and operational efficiency.

Financial Dimension

A digital representation of a physical object has the ability to integrate financial data such as material and labor costs. The availability of large amounts of real-time data and advanced analytics enables businesses to have a better idea of whether the decisions made within a production value chain are financially sound.

Conceptual Development of Digital Twin

Early experiments with design concepts in a model predicting dynamic behavior provide powerful insights. This allows engineers to make more informed decisions at the beginning of the design process. Engineers can predict stable state and transient loads on actuators during task cycles long before the first build. To ensure proper performance, control engineers can test against the digital twin using common automation software and PLC hardware. They can also test their code before hardware integration, resulting in properly tuned controls across the system.

Internet of Things, IoT, and Data Collection from the Field

By combining sensor technology with simulation, we embark on a path that leads to new innovations. Sensors can collect vast amounts of data by allowing the digital version to behave like a physical object. Running the digital twin alongside the real machine can help infer how each machine works, when it will need repair, or how it could work more efficiently. The dynamic response of Digital Twin is based on solid physical laws, so internally calculated properties can also be used as input to the control system. For example, Digital Twins can allow an engineer to quickly correct, replace, or eliminate a faulty sensor. These scenarios can lead to cost reductions and improved customer service, as customers can configure products remotely in online diagnostic systems.

Product Enrichment

The processes mentioned earlier can probably occur in real-time automation platforms and systems in a design office or operations room. Additionally, manufacturers are bringing this feature to the machine itself, so these capabilities can be offered to the operator in the workshop. These valuable features enable manufacturers to make larger innovations and differentiate themselves or their companies from competitors.

Use as a Sales Tool

Outside the engineering department, sales teams can use Digital Twins to determine customer specifications and provide accurate information to each customer. Through this digital twin technology, they can help verify the performance and operation of a machine given different loads or operating conditions without the need for an engineer’s consultation.
Digital Twins help improve both lower production costs and faster time to market by bringing these benefits together for your company or team. Embracing Digital Twin technology is crucial to staying competitive in today’s evolving digital market. If you’re not considering the benefits of Digital Twins in the rapidly developing digital world of Industry 4.0, you could be making a costly decision that leaves your company years behind.

Dijitalis, which works on Digital Twin projects, has been the solution partner of Turkey’s leading companies from past to present. Task planners and managers responsible for evaluating complex and dynamic industrial systems shoulder a heavy responsibility in shaping the future from today. In order to meet this responsibility, Dijitalis offers the world’s most advanced and powerful digital twin programs that can examine all kinds of production and logistics processes.