Machine-readable descriptions
When will the digital twin grow up?
A quick scan with a smartphone - and all the important information about the appliance is available. This is made possible by a digital nameplate QR code, which can be found on more and more devices in the process industry. For operators, this means less paper, faster access and better traceability. But this practical introduction is just the beginning. Because the QR code can conceal more than just a digital manual.
While many digitalization projects have previously relied on individual solutions and proprietary formats, a new understanding is now coming to the fore: data must be usable across the board - from the field device level to company IT. This is where the standardized digital twin comes into play. The Asset Administration Shell (AAS), an industry standard developed by the Industrial Digital Twin Association, provides industrial assets with a standardized, machine-readable description in the form of data format, interfaces and semantics. This makes it understandable across system boundaries - regardless of the manufacturer. Members such as Endress+Hauser contribute practical perspectives from automation technology to the development of the standard.
Whether sensor, valve or complete production system: the AAS describes the properties, capabilities and statuses of an asset - with a modular structure, application-specific and compatible with existing standards. This means that a device is not just a data source, but a fully integrated component of a digital process landscape.
Cooperation across company boundaries is crucial to the success of such concepts. In the "Digital Data Chain" consortium, plant operators, technology suppliers and service providers - including Endress+Hauser - have joined forces to enable precisely this consistency. The goal: a continuous flow of information along the industrial value chain.
This is based on three combined technologies and topics. Firstly, the unique identification of physical objects in accordance with IEC 61406, for example via QR codes or RFID tags. Secondly, structured digital manufacturer information in accordance with VDI 2770. And thirdly, so-called Information Exchange Platforms (IEP), on which this data can be shared and accessed in a controlled manner. The result is a standardized data source that covers planning, commissioning, operation and maintenance - regardless of the specific location or system environment.
From brownfield to greenfield: simple integration possible
This development is particularly relevant for operators of complex systems - not only in new buildings, but also in brownfield sites. The good news is that the introduction of standardized digital twins does not require a complete system replacement. Devices can be retrofitted with metal tags including QR codes, which already offer added value today. Information such as the last calibration, available spare parts or service numbers are available at the touch of a button - mobile, multilingual and up-to-date.
For new systems, devices can already be equipped with a complete digital nameplate. The user benefits from a clean digital data structure that can be integrated directly into existing systems. This reduces training costs, improves documentation and creates real process reliability. The digital product passport makes standardization even more relevant. From 2026, the EU will make this mandatory for certain product groups, such as batteries. The aim is to provide information on reparability, reprocessing and recycling digitally. This also shows that those who are already working with structured digital twins today are ideally positioned for the requirements of tomorrow.
Intelligent services and AI applications
In the long term, however, digital twins open up far more possibilities than just structured documentation. In conjunction with condition monitoring data and suitable interfaces, new fields of application are emerging: Predictive maintenance, digital services, automated spare parts ordering or AI-supported plant optimization. However, this requires a common understanding of the associated data.
In the future, life cycle data from the Asset Administration Shell could be linked with real-time data from operations in order to develop predictive maintenance strategies. In combination with data rooms, this information can even be shared securely across company boundaries - for example between operators, service partners and component manufacturers. The advantages of the standardized digital twin are also evident in the engineering process. Components can be automatically integrated into planning tools, parts lists can be standardized and variants can be mapped more easily. And because all data is available centrally, collaboration between development, purchasing, production and service is improved.
At the same time, the digital twin creates transparency across the entire life cycle - from commissioning to dismantling. This not only facilitates audits and verification, but also creates the basis for an industrial circular economy in which reuse, repair and recycling are systematically taken into account.
The twin is here - and ready for more
The digital twin is no longer a promise for the future, but a reality - provided it is standardized, interoperable and properly integrated into the system landscape. The combination of IEC 61406, VDI 2770 and AAS, together with many other standards, forms the foundation for this. For system operators, this means more efficiency, more transparency, less downtime - and a solid basis for innovation.
Michael Riester, Head of Research & Development, Endress+Hauser
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