Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System
Modern manufacturing systems are influenced by the growing complexity of mechatronics, control systems, IIoT, and communication technologies integrated into cyber-physical systems. These systems demand flexibility, modularity, and rapid project execution, making digital tools critical for their desi...
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MDPI AG
2025-03-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/15/5/2859 |
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| author | Roman Ruzarovsky Tibor Horak Roman Zelník Richard Skypala Martin Csekei Ján Šido Eduard Nemlaha Michal Kopcek |
| author_facet | Roman Ruzarovsky Tibor Horak Roman Zelník Richard Skypala Martin Csekei Ján Šido Eduard Nemlaha Michal Kopcek |
| author_sort | Roman Ruzarovsky |
| collection | DOAJ |
| description | Modern manufacturing systems are influenced by the growing complexity of mechatronics, control systems, IIoT, and communication technologies integrated into cyber-physical systems. These systems demand flexibility, modularity, and rapid project execution, making digital tools critical for their design. Virtual commissioning, based on digital twins, enables the testing and validation of control systems and designs in virtual environments, reducing risks and accelerating time-to-market. This research explores the development of digital twin models to bridge the gap between simulation and real-world validation. The models identify design flaws, validate the PLC control code, and ensure interoperability across software platforms. A case study involving a modular Festo manufacturing system modelled in Tecnomatix Process Simulate demonstrates the ability of digital twins to detect inefficiencies, such as collision risks, and to validate automation systems virtually. This study highlights the advantages of virtual commissioning for optimizing manufacturing systems. Communication testing showed compatibility across platforms but revealed limitations with certain data types due to software constraints. This research provides practical insights into creating robust digital twin models, improving the flexibility, efficiency, and quality of manufacturing system design. It also offers recommendations to address current challenges in interoperability and system performance. |
| format | Article |
| id | doaj-art-bbfcaeeb761644dcbb4363256d55d9c0 |
| institution | DOAJ |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-bbfcaeeb761644dcbb4363256d55d9c02025-08-20T02:58:58ZengMDPI AGApplied Sciences2076-34172025-03-01155285910.3390/app15052859Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical SystemRoman Ruzarovsky0Tibor Horak1Roman Zelník2Richard Skypala3Martin Csekei4Ján Šido5Eduard Nemlaha6Michal Kopcek7Institute of Manufacturing Technologies, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Applied Informatics, Automation and Mechatronics, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Manufacturing Technologies, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Manufacturing Technologies, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Manufacturing Technologies, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Manufacturing Technologies, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Applied Informatics, Automation and Mechatronics, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaInstitute of Applied Informatics, Automation and Mechatronics, Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724 Trnava, SlovakiaModern manufacturing systems are influenced by the growing complexity of mechatronics, control systems, IIoT, and communication technologies integrated into cyber-physical systems. These systems demand flexibility, modularity, and rapid project execution, making digital tools critical for their design. Virtual commissioning, based on digital twins, enables the testing and validation of control systems and designs in virtual environments, reducing risks and accelerating time-to-market. This research explores the development of digital twin models to bridge the gap between simulation and real-world validation. The models identify design flaws, validate the PLC control code, and ensure interoperability across software platforms. A case study involving a modular Festo manufacturing system modelled in Tecnomatix Process Simulate demonstrates the ability of digital twins to detect inefficiencies, such as collision risks, and to validate automation systems virtually. This study highlights the advantages of virtual commissioning for optimizing manufacturing systems. Communication testing showed compatibility across platforms but revealed limitations with certain data types due to software constraints. This research provides practical insights into creating robust digital twin models, improving the flexibility, efficiency, and quality of manufacturing system design. It also offers recommendations to address current challenges in interoperability and system performance.https://www.mdpi.com/2076-3417/15/5/2859virtual commissioningdigital twincyber-physical systemsimulationassembly systemindustrial automation |
| spellingShingle | Roman Ruzarovsky Tibor Horak Roman Zelník Richard Skypala Martin Csekei Ján Šido Eduard Nemlaha Michal Kopcek Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System Applied Sciences virtual commissioning digital twin cyber-physical system simulation assembly system industrial automation |
| title | Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System |
| title_full | Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System |
| title_fullStr | Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System |
| title_full_unstemmed | Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System |
| title_short | Development and Validation of Digital Twin Behavioural Model for Virtual Commissioning of Cyber-Physical System |
| title_sort | development and validation of digital twin behavioural model for virtual commissioning of cyber physical system |
| topic | virtual commissioning digital twin cyber-physical system simulation assembly system industrial automation |
| url | https://www.mdpi.com/2076-3417/15/5/2859 |
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