Digital Twin
The Digital Twin solution is a comprehensive IIoT platform for equipment monitoring, 3D visualization, and predictive analytics in manufacturing environments. It collects real-time data from industrial equipment via OPC-UA, MQTT, Modbus, REST API, and PLC protocols, applies condition-based alarm rules, and renders live 3D digital twins using Unity, Unreal Engine, or WebGL. S-Tier extensions add simulation engine (what-if analysis, physics-based models), predictive ML (RUL, anomaly detection), digital thread (full lifecycle traceability), 3D scene management (asset placement, annotations), edge computing (device management, OTA deployment, protocol conversion), time series analytics (derived tags, aggregation, historian integration), asset performance management (OEE, MTBF/MTTR), and complex event processing (CEP).
Solution Scale
| Category | Count | Description |
|---|---|---|
| Tables | 43 | 41 domain + 2 system |
| Relationships | 75 | 21 base domain + 24 S-Tier domain + 28 SYSTEM_REF + 2 orphan |
| Workflows | 6 | Data collection, alarm lifecycle, simulation execution, predictive maintenance, edge deployment, digital thread change |
| Admin Screens | 24+ | Lists / dashboards |
| Dashboard Widgets | Configurable | Real-time charts, gauges, status maps, alarm lists, twin viewers |
Core Domains
Document Structure
| Document | Contents | Tables |
|---|---|---|
| Data Collection | Data Sources, Equipment Assets, Data Tags, Tag Groups, Tag Group Tags, Collector Configs, Collected Data | 7 |
| Monitoring & Alarms | Alarm Rules, Alarm Events, Alarm Notifications, Dashboards, Dashboard Panels, Data Retention Policies, System Health | 7 |
| 3D Twin Visualization | Twin Models, Twin Data Mappings, Twin Sessions | 3 |
| S-Tier Extensions | Simulation Engine (4), Predictive ML (4), Digital Thread (3), 3D Scene (3), Edge Computing (3), Time Series (3), Asset Performance (2), Event Processing (2) | 24 |
Menu Groups
| Menu Group | Primary Screens |
|---|---|
| Data Source (CloudServerOutlined, production) | Data Source List, Equipment Asset List, Data Tag List, Tag Group List |
| Data Collection (CloudDownloadOutlined, production) | Collector Config List, Collected Data History |
| Real-time Monitoring (DashboardOutlined, production) | Dashboard Settings, Dashboard Panels, Comprehensive Monitoring Dashboard |
| Alarm Management (AlertOutlined, production) | Alarm Rule List, Alarm Event List, Alarm Notification List |
| 3D Twin (RocketOutlined, production) | Twin Model List, Twin Data Mappings, Twin Session List |
| Simulation Analytics (DashboardOutlined, production) | Simulation Dashboard |
Workflow List
| Workflow | Nodes | Trigger | Key Process |
|---|---|---|---|
| Data Collection (WF1) | ~10 | Collector start | Initialize -> Connect data source -> Subscribe tags -> Collect data -> Quality check -> [Good -> Store / Bad -> Log error] -> Update last value -> Continue |
| Alarm Lifecycle (WF2) | ~12 | Threshold breach | Detect -> Evaluate rule -> [Threshold/Rate/Deviation/Pattern] -> Create event -> Send notification -> [Acknowledge -> Investigate -> Resolve -> Record root cause] -> Close |
| Simulation Execution (WF3) | 12 | Scenario trigger | Start -> Validate scenario -> Load parameters -> Prepare model -> Execute -> [Success -> Analyze -> Calculate KPI -> Generate report -> [Apply to operations / Hold] / Failure] -> End |
| Predictive Maintenance (WF4) | 14 | Prediction cycle | Start -> Collect sensor data -> ML inference -> [Anomaly detected -> Calculate RUL -> [Urgent (under 30d) -> Emergency maintenance -> Create work order -> Notify / Warning (under 90d) -> Plan -> Approve -> Schedule / Normal -> Continue monitoring] / Normal] -> End |
| Edge Deployment (WF5) | 10 | Deployment request | Start -> Validate package -> Select target devices -> Approval -> [Approved -> OTA deploy -> [Success -> Verify / Failure -> Rollback] / Rejected] -> End |
| Digital Thread Change (WF6) | 11 | Change request | Start -> Register change -> Auto impact analysis -> Review impact scope -> Approval -> [Approved -> Apply change -> Update affected nodes -> Record trace / Rejected -> Record rejection reason] -> End |
Cross-Solution Integration
| Integration Target | Integration Details | Reference Method |
|---|---|---|
| MES | Equipment asset-to-MES equipment linkage | data_sources.mes_equipment_id -> MES equipment ID |
| MES | Equipment asset cross-reference | equipment_assets.mes_equipment_id -> MES equipment ID |
| EAM | Predictive maintenance work order creation | WF4 -> EAM work order system |
| Historian | Time series data synchronization | dt_historian_connections -> OSIsoft PI / Wonderware / InfluxDB / TimescaleDB |
The Digital Twin solution supports a wide range of industrial communication protocols including OPC-UA, Modbus TCP/RTU, MQTT, PROFINET, EtherNet/IP, BACnet, FINS, and MC Protocol. Edge devices handle protocol conversion and data aggregation before forwarding to the central platform, enabling connectivity with PLCs and sensors from all major manufacturers.