IoT adds the potential to take a major step forward by having a simulation connected to the product or process through the IoT executing in near real time, just in time or in replay mode to aid in operating and maintaining the product or process. A digital twin is a real-time, virtual copy of an actual operating machine that provides insight into individual product performance and maintenance. Sensors on the machine relay data — temperature, pressure, flow rate, voltage, loading, etc. — to the digital twin, and the twin evolves in step with the machines working environment.

The simulation-based digital twin concept incorporates the physical product or process, the simulation models and the connections that facilitate communications between the two. The digital twin may consist of a simulation model created with ANSYS 3D physics solvers, Simplorer and SCADE products that has been developed to duplicate the current condition of the product or process, such as by incorporating wear or degraded performance into the simulation model. The data from sensors connected to the product or process may be used to provide real time boundary conditions for the digital twin. The digital twin results can be calibrated based on the operation of the actual product or process. These enhancements to the digital twin provide the potential to improve its predictive capabilities far beyond what can be obtained in the product design process. The predictions made by the digital twin can be used to determine the root cause of performance problems, evaluate results of different control strategies, determine optimized maintenance schedules, etc. The digital twin can also provide information about the product or process that cannot be measured with sensors such as providing flow velocities through internal passages. The end result is that digital twins can be used to substantially increase the performance, reliability and operating cost of the product or process.