How can digital twin tools improve PLC-controlled systems?

A PLC-oriented response to the use of Digital Twins and the implementation of Industrial DevOps and TechOps practices: 1- Digital twins offer a virtual yet dynamic representation of physical systems, enabling the creation of Virtual PLCs or Soft PLCs, which lead to significant improvements in system flexibility. 2- Industrial DevOps streamlines the development and operation of automation software, fostering a more agile and responsive manufacturing environment. 3- TechOps, integrating technical operations with strategic oversight, ensures continuous improvement and optimal performance.

While I find the concept of digital twins logical, translating it into practice poses challenges. For example, when dealing with machines using analog signals, creating an accurate digital twin demands precise signal sampling. Inadequate sampling speed may distort the real-world representation. Moreover, achieving accurate data sampling might entail additional, sometimes costly, hardware, potentially rendering the twin's cost impractical.

Virtual Representation: Digital twin tools create a virtual replica of physical objects or systems. This includes not only the geometry but also the behavior, characteristics, and dynamics of the real-world counterpart. Real-time Data Integration: They often integrate with sensors and other data sources to capture real-time information about the physical system. This allows the digital twin to reflect the current state of the actual object or process

While I find the concept of digital twins logical, translating it into practice poses challenges. For example, when dealing with machines using analog signals, creating an accurate digital twin demands precise signal sampling. Inadequate sampling speed may distort the real-world representation. Moreover, achieving accurate data sampling might entail additional, sometimes costly, hardware, potentially rendering the twin's cost impractical.

Reduced Development Time and Cost: Digital twin tools allow for thorough testing of PLC logic and system configurations in a virtual environment before physical implementation. This reduces the time and cost associated with hardware prototyping and debugging. Enhanced Performance and Quality: With digital twins, you can fine-tune PLC logic and system parameters for optimal performance under various conditions. This helps in achieving better efficiency, accuracy, and overall system quality.

Simulation and Testing: Digital twins enable detailed simulation of PLC/DCS-controlled systems. Engineers shall be able to test and validate PLC programming in a virtual environment before implementation, reducing the risks and costs associated with physical testing. Optimization and Efficiency: Digital twins can analyze data from PLC-controlled systems to identify inefficiencies or bottlenecks. This information can be used to optimize processes, improve system performance, and reduce energy consumption. Training: Digital twins can serve as an effective tool for training operators and technicians. They provide a safe and realistic environment to learn how to operate and troubleshoot PLC systems without the risk of damaging equipment.

Look for a tool that seamlessly integrates with your existing PLC development environment. This includes compatibility with programming software, data exchange capabilities, and ease of transferring logic and configurations between the digital twin and the physical PLC.

Access the simulation settings and parameters menu to configure various aspects of the simulation: Simulation Mode: Choose between real-time or offline simulation modes. Duration: Set the length of the simulation. Resolution: Define the time or step intervals for simulation updates. Variables: Specify the system variables to be monitored during the simulation. Initial Conditions: Set the starting state of the system. Inputs and Outputs: Configure the inputs and outputs that will be used during the simulation. Events: Define any specific events or triggers that should occur during the simulation.

Clear Objectives and Scope: Define what you want to achieve with the digital twin in relation to the PLC system. This could include objectives like system optimization, predictive maintenance, training, or troubleshooting. Accurate Modeling: Ensure that the digital twin accurately represents the physical PLC-controlled system. This includes detailed modeling of hardware components, software logic, and environmental factors. Data Integration and Management: Establish robust data integration processes. This involves ensuring real-time data synchronization between the physical system and its digital twin. Also, manage data effectively for analysis, ensuring data accuracy, security, and compliance with privacy regulations.

Scalability and Flexibility: Design the digital twin setup to be scalable and flexible to adapt to changes in the PLC system, ie. upgrades, expansions & new integrations. Documentation and Compliance: Maintain comprehensive documentation of the digital twin setup, including data sources, modeling techniques, and use cases. Ensure compliance with industry standards and regulations. Risk Management and Security: Address cybersecurity concerns by implementing robust security measures to protect the digital twin & associated data from unauthorized access or attacks. Stakeholder Engagement: Involve key stakeholders in the planning and implementation stages to ensure that the digital twin aligns with broader organizational goals and user needs.

My use of the digital twin is in reliability as I use RCFA tools to build in areas of the digital twin as a means to prevent or rapidly recover from degrees of failures (alarms, faults, and events). My research is now specific to VFDs, but I see the practical applications joining PLCs as the complete system develops. For now, the current generation of VFDs does not go far enough, IMHO, as they are designed to be agnostic to the application and motor design. I aim to bring the application into the context and create better reliability.