The Importance of Digital Twins in a Connected World

What is a Digital Twin and How Can it Help You

Imagine having a high-tech mirror image for real-world objects and processes – you’ve just imagined the basics of Digital Twin technology. Digital twins are created to flawlessly mimic physical things like products, systems and processes, not only in terms of image and look, but also with regards to behaviour. This virtual twin steps up for crucial tasks such as: 

• Simulation 
• Integration 
• Testing 
• Monitoring and maintenance 

The core idea arose from the need to optimise product manufacturing processes by studying, understanding, analysing, and providing feedback on the entire process. 

Digital Twin software companies extend their focus beyond mere replication, embracing transformative technology with a multitude of benefits. Key among these is the seamless integration of physical and digital realms, greatly enhancing overall efficiency. This technology uses live data from sensors to help manage and respond to changes in assets, making businesses better overall.  

Digital twins also enable a comprehensive analysis of historical data, revealing trends and patterns crucial for strategic decisions. This accelerates various processes, shortens the time-to-market for products and services, and significantly reduces risks, thereby increasing the likelihood of success in real-world implementations. 

Industry 4.0 and the Emergence of Digital Twins

The inception of Digital Twins can be traced back to the Industry 4.0 revolution: a convergence of the physical and digital realms, with the purpose of instigating transformative change. 

In practical terms, the real-world simulation of objects enhances our comprehension of entire ecosystems. Real-time data enables virtual replicas to operate in harmony with reality, offering the advantage of foresight. This approach, known as real-world simulation, expedites decision-making without direct interaction with physical objects. 

For instance, a digital twin of an aircraft engine enables simulations of various flight conditions, optimising fuel efficiency and aerodynamics. Similarly, a digital twin of a high-wear part facilitates simulated operations under different conditions, aiding in preventive maintenance and predictive modelling. 

‘In a world evolving at an ever-increasing pace, this technology is one invaluable partner to consider,’ adds Paulo Ferro, our Principal Engineer for Manufacturing and Digital Commerce & Retail.

The Technology Behind the Operation of Digital Twins

Combining different technologies produces virtual models that closely mimic the real world. Key technologies include: 

1. Modelling: Using 2D or 3D techniques to replicate virtual models of physical objects, both in terms of appearance and behaviour.
2. IoT Sensors: Covering various metrics like temperature, humidity, pressure, vibration, these sensors provide real-time or near-real-time information.
3. Real-Time Location Systems (RTLS): Automatically finding and monitoring where objects are, especially indoors where GPS doesn't work well, or where greater accuracy is important. RTLS can use technologies like Radio Frequency Identification (RFID), Wi-Fi, Bluetooth Low Energy (BLE), Ultra-Wideband (UWB), or AI with image recognition.
4. Big Data: As a technology that generates a large amount of information, digital twins use Big Data management systems to store, process and enable data analysis.
5. Data Analysis: Examining, cleaning, transforming and modelling data to discover valuable information.
6. Artificial Intelligence (AI) and Machine Learning (ML): Processing data to optimise processes modelled by digital twins through pattern and trends recognition.
7. Computing Infrastructure: Used to support all other necessary technologies. Clouds tend to be used for scalability, connectivity, security, and various management modes.
8. Cyber security: Crucial for safeguarding against unauthorised access and undesirable operations since there is a direct connection between digital twins and the real world.
9. Communication Protocols: Ensuring seamless communication between various components of a digital twin platform (TCP, UDP, HTTP/HTTPS, MQTT, LoRaWAN, Bluetooth, etc). 
10. Augmented Reality (AR) and Virtual Reality (VR): Facilitating immersive and intuitive interaction with digital twin models and virtual objects, especially in maintenance training.
11. Edge Computing: Placing processing capacity closer to sensors for swift action, reducing latency and bandwidth requirements for the entire ecosystem. 

Optimising Returns: How to Increase ROI with Digital Twins  

Venturing into the realm of Digital Twin technology, we find a world brimming with challenges and opportunities in many different fields. The seamless integration of complementary technologies is imperative, forging solutions to specific business objectives. 

Digital twins present RoI opportunities through: 

• Optimising operational efficiency 
• Improving product development 
• Reducing downtime 
• Mitigating risk 
• Increasing sales 

Don’t forget that to calculate the ROI, it is necessary to quantify as much as possible the gains obtained in these different domains, against the costs of implementing and maintaining digital twin software. 

Beyond Digital Twins Horizon: Twinzo Partnership

Critical’s commitment to Digital Twins goes beyond this article: we are thrilled to announce our partnership with Twinzo, a company sharing our passion for the limitless possibilities of Digital Twins. Together, we’ll show you how to unlock new horizons, sharing insights, experiences, and innovations.  

As we delve deeper, we promise to unveil practical advantages of different scenarios and specific business areas, to help you and your team conquer challenges and empower you to embrace the future confidently. 

For an insightful discussion about Digital Twins, feel free to contact Paulo Ferro, our Principal Engineer for the Manufacturing and Digital Commerce & Retail sectors at Critical.  

Your digital twin journey begins here!