A Digital Twin Based Framework for Real-Time Machine Condition Monitoring.

Condition Monitoring (CM) is an important approach to extending the life of complex equipment by forecasting the outcome of an event before catastrophic failure occurs. Recent advancements in digital twins (DT) offer additional benefits to machine condition monitoring. In this study, a framework based on DT for real-time condition monitoring of industrial machines is proposed. The multi-layer DT framework consists of a physical entity (PE), virtual equipment (VE), edge device, fidelity service and digital twin services. The virtual equipment is a replica of the physical entity or the monitored machine. It also contains a cloud platform to store data online and an application to interface with the cloud enabling users to check the data remotely. The fidelity service ensures conformity between the PE and the VE. The digital service provides optimal operation and maintenance schedules based on the data from both physical and virtual spaces. The integration of the edge layer enables real-time handling of high-frequency machine data for effective health monitoring. The validity of the proposed framework is demonstrated with a case study based on monitoring a critical component of an industrial drivetrain test rig. The features of the framework allow end-users to visualize the component's real-time health status remotely.