In today’s era of factories and automation techniques, Factories are no longer connected only by physical walls and machines; they are interconnected through digital platforms and smart technologies. Instead, Digital Twin technology has emerged, which creates an exact virtual replica of industries on a computer screen. This screen monitors real-time data of your factory and shows all the ongoing activities in their exact form.

Digital twins system helps to analyse your machine performance, predictive maintenance, or performance optimization. In this blog, we will discuss digital twin: Building a virtual factory model with your IoT platform. This twin system helps to increase product efficiency in factories or reduce downtime.

Table of Contents

What is a digital twin system?

A Digital Twin is a technology that creates a complete blueprint of your entire factory, including machinery, production lines, and all activities, directly on your screen. It measures everything happening inside the factory. The machines are equipped with sensors that send data to the system, showing what is going on both inside and outside the machines, and this information is then reflected on the screen.

How does the digital twin system work with IoT platforms?

Digital Twins are a smart and effective way to monitor factories efficiently, as well as to analyze the activities of factory machines. But the most effective results come when they are connected with IoT (Internet of Things) platforms. This way, whatever physical activity is happening inside the factory, all that data is transmitted to the digital replica, which then structures and presents it.

It collects all real-time factory monitoring from machines or sensors. Like temperature, energy consumption, parts analysis, or other factors.
Data transmission sends data into information and the IoT cloud-based platforms. That analysis stores the data.
This automatically updates the data, as it receives real-time information from the cloud about the machine, and shows updates just like a live broadcast of the factory.
Proper machine analysis and prediction of future machine issues. So that the smart factory’s machines can work in a more effective and efficient way.

What are the benefits of choosing virtual factory models?

Enhance efficiency: A virtual factory model always helps manufacturers to easily monitor every activity of their business, whether it is production or machines. That’s why it works with real-time data and manages every type of error that may occur in machines in the future, which could otherwise affect production efficiency.

Predictive maintenance: This is a common problem for every factory and industry. A sudden machine breakdown can halt their operations. IoT sensors analyze and monitor every activity of your machine, such as electric voltage, working efficiency, and temperature anomalies. The purpose of these industrial digital twins is that they detect potential failures before the machine actually breaks down, allowing faulty parts or issues to be fixed in time. As a result, time, money, and working efficiency are utilized more effectively.

Cost saving: It also helps significantly in saving costs such as raw materials, labor, and energy. It analyzes the production line and provides insights on the proper use of raw materials while reducing wastage, which additionally lowers bills. This has played a profitable role in the development of factories.

Increase product quality: These twin systems monitor every activity of the company, which gives them exact and up-to-date information. They analyze this data and identify both human and machine errors, ensuring that the quality of your product improves even more, and production can be increased easily.

Better innovation: These systems also analyze the innovative designs of products along with their production cost and timing. Due to this twin system, a lot of costs are saved, because by making changes in this small duplicate setup. We can analyze whether a new implementation is suitable for our project or not.

Key implementations of the digital twin systems

It has effectively monitored machine health, heat, production speed, and all its activities in manufacturing units. IoT sensors provide early warnings about whether or not any issues are likely to occur in the machine.
Digital twins system contributes to the medical or healthcare industry because doctors visualize the digital twin of a patient’s internal or external organs.
It optimizes Giant power plants on a daily basis, like their performance, turbines, fuel usage, and energy output.
With its help, planning for public safety, traffic flow, and energy consumption can be done, which is beneficial for the public.
It is implemented in warehouses to track their production efficiency or routine optimization.

Why choose Unseen Era for digital twin: building virtual factory models with your IoT platform?

Unseen era is the deep expertise in industrial automation technology. Their excellent engineering solutions provide you with the solution for various industries, like the pharmaceutical, industrial, or chemical industry. This company builds its strong presence in the market because of its high-quality products and customer satisfaction.

Here are solutions of Unsen Era: