The digital twin becomes a game changer

The digital twin (DTw) plays a central role in Industry 4.0. It links the physical and digital worlds and enables the consistent use of data across the entire life cycle of a product. It is therefore the symbol of the IT-OT convergence that has begun.

For data transfer to be interoperable and scalable, a common digital language (semantics) or standardization is required - ideally both. The Asset Administration Shell (AAS) offers a standardized metamodel for data modelling that can be used as a basis.

At the same time, the Industrial Digital Twin Association (IDTA) standardizes sub-models as templates, so-called SMTs (sub-model templates), and offers the possibility of integrating semantic elements into the concept via so-called semantic IDs. This allows DTw to develop its maximum effect. "Proprietary formats are therefore of little use," emphasizes Detlef Tenhagen from Harting. "Interoperability only becomes a reality with a standardized description. The more we load a digital twin with comprehensible information, the more it will develop into a complete simulation-capable model of reality." This requires a technical format that must be provided uniformly by everyone and can also be used by everyone, as is the case with the IDTA based on the basic standardization by IEC TC65/WG24.

Thanks to clearly defined submodels and standardized interfaces (API), the AAS enables seamless integration into existing IT systems such as ERP, MES, PLM or digital ecosystems. Machines, products, components and software can communicate with each other in a standardized way - even across company boundaries.

Digital twins pave the way for change

The modular structure of the DTw enables the provision of basic information in the form of these templates, such as technical data or manufacturer information, specific content such as maintenance instructions or recycling information, as well as dynamic data such as energy consumption or_{CO2 footprint}. Companies can set up and expand the DTw as required. Particularly in light of the sustainable transformation of industrial production, it is important that the Digital Product Passport (DPP) can also be integrated into the AAS. "Over 80% of a product's environmental impact is decided at the concept stage, which requires a fundamental shift in the way we ideate and design," says Tony Hemmelgarn, President and CEO of Siemens Digital Industries Software. "To be effective, companies must evaluate the overall environmental impact of a product in addition to its features, cost and quality. By using modern technical solutions, companies can assess these aspects at the design and engineering stage and make informed decisions based on accurate, up-to-date data."

The transformation of production must take into account all variables that influence the environmental impact of a product. With topology optimization, generative engineering and additive manufacturing for digital tool twins, for example, material waste and energy consumption during production can be reduced. More efficient production lines can be planned using simulations and energy consumption can be optimized in advance. Predictive maintenance models, for example, allow companies to monitor a product throughout its entire life cycle and act proactively. "It is important to identify changes that have a practical impact on every point of the digitally networked data and information that is generated throughout the entire product life cycle," says Hemmelgarn. "These changes are stored in the digitally networked data and help companies to manufacture products not only faster, better and more profitably, but also more sustainably." Sustainability is not a retrofitted element in the life cycle of products, but an integral part of the entire digitalization process, which begins in the design and construction phase. As dynamic software models, the DTw enable real-time monitoring and can therefore improve process efficiency.