The growing demand for faster and better quality products is creating increasingly complex challenges for the automation industry. As virtual commissioning and digital manufacturing become more prevalent, machine builders need to optimise design processes to increase productivity and profitability. To remain competitive, companies must adapt to these changing demands and embrace advanced technologies. At IDM-Systems Zrt. we offer an advanced Digital Twin methodology to address these challenges, providing integrated and future-proof solutions.
What is Multi-Level Digital Twin?
In the world of cyber-physical systems, we often talk about digital models, digital shadows and digital twins. The concept of a digital twin is that there is a continuous stream of data between the physical system and its virtual counterpart - this is where virtual commissioning comes in. This technology is already widely used today, particularly in the automotive industry. At IDM-Systems Zrt. we have further developed this concept, which consists of two main elements: the so-called Digital Asset Twin and the so-called Operational Twin.
- Digital Asset Twin: A periodically (on-demand) run, functionally validated 3D model with virtual peripherals (e.g. HMI, PLC, robot programme). This model allows running real PLC, robot and HMI programs, making it ideal for classical virtual commissioning (testing and optimization of PLC programs) and training purposes. All this is kept up-to-date and in sync with real operation.
- Operational Twin: A data-driven, logical twin that runs continuously in sync with the real system. It maintains a real-time data link with the physical system and includes modules such as Predictor, Energy Optimizer and Correlation Explorer to maximize the information that can be extracted from the data.
These two models are tightly coupled through a framework and several interfaces to form a functional, integrated system. The large amount of real-time data integrated in this way allows the system to communicate with higher level SCADA and MES systems in factories.
Main advantages of multi-level digital twins
The use of multi-level digital twins offers significant benefits.
The Digital Asset Twin: enables faster start-up, better preparation and training of staff (operators, maintenance, programmers) and allows "what if" analyses on existing production lines. It also facilitates the evaluation of the impact of logical decisions and virtual validation before physical changes are made.
The Operational Twin uses large amounts of real-time data to support data-driven decision-making (for example, in cycle time reduction and process optimisation).
It improves efficiency, increases system flexibility and supports continuous data-based monitoring.
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Overall, the concept integrates a streamlined data flow, can be easily extended with additional modules thanks to its modular design, while ensuring data consistency and exploring data-based relationships and correlations. It supports the modelling of complex relationships, promoting sustainability and resource efficiency. A COPA-DATA works closely with Zenon SCADA to improve the customer experience, allows operators and maintenance staff to be trained in advance and increases performance. It also supports pre-optimised system design and development to ensure efficient integration, fast start-up and real-time data exchange. Finally, by exploiting big data, the model can be enhanced with AI- and machine learning-based modules to further improve real system performance.
The evolution of digital twins is revolutionising industries with real-time monitoring, predictive maintenance and process optimisation. The next generation, multi-level digital twin concept promises even greater possibilities, with advanced simulation capabilities and deeper integration between different systems. As this technology evolves, it will further drive innovation in production, increasing efficiency, reducing costs and providing even more accurate data-driven decision making for future developments.
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