Digital Twins

Digital representation of the real world

We offer solutions

We implement comprehensive digital twin solutions that enable companies to accurately visualize and control their physical assets and processes virtually.
Our technologies capture, analyse and visualize real-time data to support informed decision-making and optimization.

How we achieve our goal

Data is collected by sensors, processed asynchronously via an IoT platform, aggregated and persisted in the backend and displayed in real time in the frontend. An adapter layer enables integration into existing systems. Security is ensured by a roles and rights system. Success is measured using defined KPIs.

This is our key

Our solutions are tailor-made, flexible and scalable so that they can be optimally adapted to the specific requirements of each customer. Through a holistic approach and a clear focus on customer needs, we create real added value and sustainable efficiency gains.

Sensors

The actual status (e.g. of water, electricity and heat output) with all relevant parameters is read out in real time via sensors and device interfaces.)

Actuators

Control of all elements such as heating, air conditioning or shading.

Networking

Connection of the sensors to a cloud platform to ensure reliability and remote access.

User interface

All data and functions at a glance in an intuitive user interface: Digital Twins offer convenient reporting and control functionality that supports people in their tasks.

Aggregation

Recording and evaluation of all resulting data for simulation, comparison and historical observation.

Asset tracking and management

Real-time monitoring and management of mobile devices and assets, which record information such as location, status and usage, significantly increases efficiency and safety. On a large construction site, for example, data can be collected from construction machinery and tools, including location, operating hours and maintenance status. This information enables continuous monitoring of the current condition and usage of assets, which not only helps to optimize the use of resources, but also significantly reduces the risk of loss and theft.

Process optimization

By simulating and analyzing production processes, bottlenecks can be identified and efficiency increases can be achieved, which both increases productivity and reduces operating costs. Digital twins can be used in a production plant to virtually map and analyze the entire production process. For example, data on material flow, machine utilization and production times are recorded and evaluated in real time. These simulations make it possible to precisely identify inefficient processes and bottlenecks. On this basis, targeted measures can be taken to optimize production processes.

Monitoring and control

By using digital twins in a large refrigeration system, compressors and refrigeration units can be monitored and controlled in real time. Data such as temperature, pressure and energy consumption are continuously recorded and analyzed. This real-time monitoring makes it possible to adjust operating parameters immediately in order to optimize processes and cooling performance and minimize energy consumption. This improves the efficiency of the cooling system and makes the control of the appliances more precise and effective.

Predictive maintenance

By continuously monitoring and analyzing machine data such as vibration, temperature and operating hours, maintenance requirements can be identified and predicted at an early stage. On a CNC machine, this real-time data makes it possible to identify signs of wear or impending failures so that maintenance measures can be planned in a targeted and timely manner. This leads to a reduction in downtime and maintenance costs.

Supply Chain Management

The use of real-time data and simulations to monitor and optimize the entire supply chain allows for a significant increase in transparency and efficiency. In a global production company, digital twins enable seamless monitoring of the supply chain, from the procurement of raw materials to the delivery of end products. Data on stock levels, transport times and production capacities are recorded and analyzed in real time. This allows bottlenecks and delays to be identified and rectified at an early stage. These measures not only improve the transparency and efficiency of the supply chain, but also reduce operating costs and increase customer satisfaction.

Fleet management

Real-time monitoring and analysis of the vehicle fleet, including engine performance, fuel consumption, maintenance requirements and current location, enable fleet operations to be optimized and wear and tear to be reduced. A construction company can use digital twins to monitor construction equipment such as excavators and bulldozers. Data on engine performance, fuel consumption, operating hours and location are continuously recorded and analyzed. This real-time information makes it possible to identify maintenance requirements at an early stage and use the machines efficiently, which leads to a reduction in wear and tear, improved capacity utilization and lower operating costs.

Energy consumption optimization

Monitoring and analyzing the energy consumption of systems and buildings offers the opportunity to identify potential savings, reduce energy costs and improve sustainability. In a data center, digital twins can be used to monitor the energy consumption of servers, cooling systems and other critical infrastructure in real time. Data on power consumption, cooling performance and server utilization is continuously collected and analyzed. This real-time monitoring helps to identify inefficient usage patterns and take measures to optimize energy efficiency. This reduces energy costs and significantly increases the sustainability of data center operations.

Facility management

The management and optimization of building operations and maintenance can be effectively controlled through real-time monitoring and analysis of building data, resulting in reduced operating costs and improved building performance. In a modern office complex, digital twins can be used to monitor the operation and maintenance of the building in real time. Data on heating, ventilation, air conditioning (HVAC), lighting and security systems is continuously collected and analyzed. The result: reduced operating costs and improved overall building performance.

Product development

Simulating and testing new products in a virtual environment makes it possible to identify problems in development at an early stage. This shortens development cycles and reduces costs. In the development of new electric vehicles, digital twins are used to simulate and test the design and performance of batteries and drive systems. These simulations help to identify potential problems such as overheating or inefficient energy distribution at an early stage so that adjustments can be made before physical prototypes are built.

Requirements analysis and planning

The first step in implementing a project is to clearly define objectives and use cases. The relevant stakeholders are then involved in order to identify their needs and requirements. This is followed by an analysis of the existing systems and framework conditions. On this basis, the technology selection is made, whereby suitable sensors, IoT platforms, backend systems and visualization tools are determined.

Data integration and acquisition

The next step in the project involves data modeling, in which a data model for the digital twin is planned and implemented. This is followed by the data connection, in which sensors, actuators and device interfaces are connected to the platform and the data is recorded. To ensure the integrity of the recorded data, mechanisms for validating and cleansing the data are defined to ensure high data quality.

Implementation

Another important step is the design and interaction concept, in which a consistent and human-centered user experience is developed. At the same time, the backend or cloud infrastructure is set up to implement the data processing logic, aggregation and persistence. The front end is then developed, creating user interfaces for visualization and interaction. Finally, security measures are integrated, including a roles and rights system and data protection measures to ensure the security and protection of the data.

Testing and optimization

A key part of the project is to carry out system tests in order to regularly and comprehensively check functionality, performance and security. At the same time, feedback from users and stakeholders is continuously collected and analyzed. Based on this feedback and the key performance indicators (KPIs), adjustments and optimizations are made to ensure continuous improvement of the system.