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Concept

Digital twin

Test the copy, spare the machine.

HOW IT WORKSA model of theobject is builtfrom its drawingsSensors on the realobject send readingsThe readingsupdate the model toshow the object'spresent conditionEngineers inspectthe model orrun tests on itThe results guiderepair and operationof the real objectTests on the twin cannot damage the real object, and the twin shows its condition at present.HOW IT WORKSA model ofthe object isbuilt fromits drawingsSensors onthe realobjectsend readingsThe readingsupdate themodel to showthe object'spresentconditionEngineersinspect themodel or runtests on itThe resultsguide repairand operationof thereal objectTests on the twin cannot damage the real object, and the twin shows its condition at present.HOW IT WORKSA model of the object isbuilt from its drawings↓Sensors on the real object send readings↓The readings update the model to show theobject's present condition↓Engineers inspect the model or run testson it↓The results guide repair and operation ofthe real objectTests on the twin cannot damage the real object, and thetwin shows its condition at present.
Readings from sensors on a real object update its digital model, and engineers check or simulate the model instead of the real object.
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A digital twin is a digital copy of a real structure or machine, kept up to date with data from it, so it can be checked and simulated without touching the real one. The copy can be a 3D model of a building, a model of a jet engine, or a model of a whole factory. The word "twin" is used because it follows the real object as it changes.

Here is how it works in general. First, a model of the object is built from its drawings and specifications. Sensors on the real object then send readings, such as temperature, vibration or position, and these update the model so that it shows the object's present condition. Engineers can look at the model to see what is happening inside, or run tests on it. For example, they can ask what would happen if the load doubled. The answer comes from the model, so the real object is not put at risk. The results guide decisions on repair and operation.

Engineers describe three levels. A digital model only holds the design. A digital shadow is also updated with live readings. A full digital twin can also send commands back to the real object. The model must be calibrated, which means its answers are compared with the real readings and adjusted until they agree. A twin can mislead when a sensor gives wrong numbers, or when the object is repaired and the twin is not updated. More detail in the model needs more computing power, so engineers include only the details that matter for the question being asked.

Take, for example, a jet engine with sensors that report its temperatures on each flight. The twin shows how much life each blade has left and predicts when it needs repair; see jet engines. Consider a building. The twin shows the position of every pipe and wire, and the live temperature of each room; see building information modelling. Imagine a chemical plant. Operators test a new setting on its twin before changing the real plant; see plant digital twins.

A twin is built on the digital thread and sensor data from industrial IoT. It enables predictive maintenance and uses engineering simulation. Related pages are autonomy simulation and operator training simulators.

How is it different from a plain simulation? A simulation is a model run with assumed numbers. A digital twin is fed live data from one real object, so it shows that object's state now.

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