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Digital Twin - Building the Gap Between Real Time & Virtual World

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Digital Twin - Building the Gap Between Real Time & Virtual World

Due to the increased competition in the market, it is crucial for business owners to comprehend customers' expectations and create what their customer wants. Many business people are trying to understand what digital twins are all about.

This article offers you a thorough explanation of digital twins, including their benefits, advantages, workflow, and steps to create.

What is a Digital Twin?

 A virtual replica of a physical object is called a digital twin. A thing could be a car, a bridge, a building, or a jet engine. Data that is mapped onto the virtual model is gathered by sensors connected to these real assets. People may view important details about how the actual thing functions in the real world due to the digital counterpart.

Digital twins are now highly developed due to technologies like Artificial Intelligence, Machine Learning, Deep Learning, IoT, sensor, simulation, networking, and big data.

Working Principle of Digital Twin

  • The information generated in the physical world must be gathered in order to create and implant digital twins. 
  • Sensors and other devices that gather accurate data on the state of the process or product are used to gather this information.
  • However, this data needs to be handled and processed properly. The sensors and devices must be linked to a cloud-based system that can receive and process the data in real-time in order to handle this volume of data. 
  • After the data has been processed, a digital twin can be created as a virtual replica.
  • Real-time data from the sensors is fed into the digital twin, which then replicates what actually occurs. 
  • As a result, it enables a nearly accurate representation of potential issues that may arise during the design or operation of a process or machine and is particularly helpful for enhancing machine efficiency and behavior.
  • Because of this, it is essential that the entire process be included in the development of these digital twins; if data is gathered from every stage of the process, this virtual duplicate will be more accurate.

Why is Digital Twin Gaining Popularity?

Digital twins have several benefits as they enhance the behavior of processes and products, or, more generally, their efficiency, 

  • The use of digital twins enables you to foresee probable future issues. Along with other benefits, this decreases product faults and speeds up manufacturing.
  • Through the use of accurate information, industrial process optimization, and improvement.
  • Reduce unnecessary downtime caused by possible mistakes.
  • Since they enable the simulation of a wide range of scenarios and case studies, they lessen accidents.
  • Lowering maintenance expenses by carrying out preventive maintenance procedures.
  • Opportunities for continual development through failure and inefficiency detection in simulations.

Types of Digital Twin

Parts Twinning

Digital twinning is built on a solid parts twinning foundation. This level of virtual component representations enables engineers to comprehend the physical, mechanical, and electrical properties of a part. Building mathematical models with a sufficient level of complexity are important to forecast real-life behavior in various contexts.

Product Twins

This enables you to make the required modifications and produce a more effective design. Because of this, the product's digital twin helps to improve quality while lowering production costs and time to market. Twin products can be used to regulate a product's performance in the real world.

Process Twins

A virtual production process can generate many scenarios and demonstrate what might occur in certain circumstances. This enables a business to create the most effective production strategy. A business will be able to perform preventive maintenance as a result, avoiding expensive downtime. Production processes will be quicker, safer, and more effective.

System Twinning

Engineers can integrate, configure, and maintain an entire fleet of products that cooperate to achieve a goal in a system at a higher level via system twinning. With unprecedented testing and monitoring, industrial manufacturing systems, traffic control systems, and communication systems will all reach previously unheard-of levels of efficacy and efficiency.

How To Create a Digital Twin? 

Market Analysis

Before beginning any business, thorough market research must be carried out. Understanding the target market's size and composition would be made easier by conducting thorough market research and having a well-defined business plan. There are numerous ways to gather data on the present market.


A digital twin's design is composed of two key components,

To enable the real-time flow of operational and transactional information, choose the enabling technology that will integrate the physical asset with its digital twin. Clarity regarding the necessary device kind is also crucial.

Recognize the kinds of information needed throughout the asset's life cycle, where this information is kept, and how to utilize and access it. Create a reusable structure for the data so that it may be transferred between systems quickly and effectively.


Find out the roles and purposes of the digital twin. Will it run simulations, advanced analytics for predictive maintenance, asset control, and adjustment, and asset monitoring? The solution to this problem will reveal the extent and functionality of the digital twin and assist in identifying the kinds of devices that must be attached to the asset.


Digital twin deployment typically begins modestly, such as by monitoring a single asset component, but eventually grows. There are two approaches to carrying out the expansion, 

To give a complete image of the entire asset, organizations bring a lot more tiny digital twins.
Organizations enhance the current digital twin with more complex features like simulations.

Businesses aim to layer functionality within the digital twin to accommodate changing needs in either scenario. To grow the digital twin and keep performance, those functionalities must be added in a secure manner.

Testing and Launch

Following the development, the quality assurance team uses a variety of test cases and testing methodologies to check the product for problems. Launch the platform successfully into the market after flawless platform development.


It takes time and effort to create a platform that is relatable to your target market, and it changes when new users' needs and market demand change.

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