Virtual commissioning and real-time data: a deep dive into digital-twin technology
Key Highlights
- Digital twins go beyond static geometry by incorporating real-time data, logic and control behaviors to create a behaviorally accurate 3D model of a production system.
- Integrating decentralized drives and edge computing allows for the capture of critical operational signals, like torque, speed and energy, to ensure the virtual model remains synchronized with physical hardware.
- Virtual commissioning significantly reduces project risks by allowing teams to validate PLC logic and identify potential issues early, leading to shorter lead times and improved system reliability.
Graham Wloch is director of business development at Visual Components. He answered some questions about digital-twin technology.
What are some applications where decentralized drives might benefit an industrial system being designed and built?
Graham Wloch, director of business development, Visual Components: Decentralized drives are valuable in systems like conveyors and modular automation because they enable real-time data—speed, status, energy—to be connected into digital twins, keeping the simulation models more precise for virtual commissioning, analysis and continuous optimization.
What sorts of emerging technologies, such as edge computing, AI-assisted diagnostics or advanced simulation are being integrated into drives and inverters?
Graham Wloch, director of business development, Visual Components: Developing technologies such as edge computing, AI-assisted diagnostics, and advanced simulation are increasingly being integrated into modern drives and inverters to capture real-time data processing and predictive maintenance. This data can be leveraged within digital twins, which allows manufacturers to connect 3D systems with real operational signals for virtual commissioning, performance analysis and optimization during the automated production systems.
Speaking of advanced simulation, the definition of a digital twin can vary, based primarily on the application. What's your definition, and how are digital twins utilized within the development and commissioning processes, and what impact have digital twins had on reducing project lead times or improving reliability?
Graham Wloch, director of business development, Visual Components: A digital twin is a behaviorally accurate data driven 3D model of a production system. This goes beyond CAD geometry to include motion, logic and control behavior. These digital twins are used throughout development and virtual commissioning to validate designs, test PLC and drive logic, while identifying issues early. This helps teams shorten project lead times, reduce on-site commissioning and improve reliability before systems go into the real world.
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What kinds of data and sensor inputs are most valuable for building accurate digital twins of drive systems, and how important is it to ensure real-time synchronization between physical and virtual models?
Graham Wloch, director of business development, Visual Components: The most valuable data for accurate digital twins is motor speed, torque, current, load, energy consumption and fault states, which mirror real operational behavior. Real-time synchronization is critical because it ensures the digital twin behaves like the physical drive system at that moment, not just in theory. Maintaining real-time or near real-time synchronization between physical systems and their digital twins is especially important during virtual commissioning and optimization. This ensures the model remains a reliable basis for validation, diagnostics and continuous improvement.
Tell us about one of your company’s state-of-the-art products that involves digital twins.
Graham Wloch, director of business development, Visual Components: Visual Components 5.0 is our latest release for our digital twin and 3D manufacturing simulation platform. It enables users to model and simulate automated production systems and connect models to real PLCs and controllers for virtual commissioning. This reduces risk, commissioning time and downtime in real-world manufacturing environments.
About the Author
Mike Bacidore
Editor in Chief
Mike Bacidore is chief editor of Control Design and has been an integral part of the Endeavor Business Media editorial team since 2007. Previously, he was editorial director at Hughes Communications and a portfolio manager of the human resources and labor law areas at Wolters Kluwer. Bacidore holds a BA from the University of Illinois and an MBA from Lake Forest Graduate School of Management. He is an award-winning columnist, earning multiple regional and national awards from the American Society of Business Publication Editors. He may be reached at [email protected]
