Digital twin benefits and challenges

WITH A clear goal to make industrial automation simple, seamless and cost-efficient, it’s no surprise that digital twin technology is part of Murrelektronik’s latest innovation – Vario X – a completely decentralised automation platform. Vario-X exemplifies cabinet-free automation and with the added benefit of a digital twin, is it now possible to virtually test and optimise your machine before commissioning.

Reducing risks

"As a supplier of machine automation solutions, we see the huge impact digital twin technology has on our customers across industries," says Tanya Trojansky, global solutions engineer visualisation at Murrelektronik. "Digital twins are especially valuable in machine redesign, helping machine builders transition from classical cabinet installations to decentralised setups. This shift offers greater flexibility, scalability, and reduced downtime, but also comes with challenges like adapting hardware, integrating new technologies, and mechanical changes. Digital twins make it possible to plan, test, and train these steps in a virtual environment, reducing risks and improving communication across company departments.
 
“During the engineering phase, the digital model is key for virtual commissioning. It allows programming, testing, and validating systems in a virtual setup, cutting down on-site development time and risks. In operation, customers use digital twins for feasibility studies and process optimisation, virtually simulating their systems to find inefficiencies, predict performance, and improve workflows.

“From a practical viewpoint, digital twins are a huge advantage for training and condition monitoring. They provide immersive training for operators and enable predictive maintenance, minimising unplanned downtime and optimising resources. In addition, digital twins make retrofitting machines faster and safer, reduce engineering and programming workloads, and give customers new ways to offer services, which is especially helpful as finding skilled workers becomes more challenging.”

But all new technology has challenges, especially in the wider adoption of digital twin technology. Tanya continues to explain how easy is it to integrated digital twin technology into legacy production systems?

“A key challenge in the wider adoption of digital twin technology is not just technical—it’s about mindset. Many manufacturers still view digital twins as a complex, futuristic concept rather than a practical tool for immediate operational benefits. To fully leverage this technology, companies need to shift their perspective and see digital twins as a core part of their digitalisation strategy, rather than an isolated tool for simulation or engineering. Also, the integration process doesn’t have to be overwhelming. Step-by-step implementation is possible, starting with targeted use cases like virtual commissioning, predictive maintenance, or process optimisation," explains Trojansky.

Open standards

“One of the biggest enablers for this shift is open standards and interoperability. Many legacy production systems were built as closed environments, with proprietary interfaces and data formats that make it difficult to connect different machines, controllers, and software solutions. Without standardised communication protocols, integrating digital twins into existing production lines can become expensive and time-consuming. This is why industry-wide adoption of open standards, such as OPC UA and MQTT, is critical. These protocols enable seamless data exchange between machines and digital twin platforms, allowing for greater scalability and flexibility.

“Ultimately, the challenge isn’t just about technology—it’s about rethinking how we approach automation. Companies that foster a culture of digital adoption and invest in workforce training will gain the most from digital twin technology. Those who resist this shift may struggle to remain competitive as the industry moves toward greater connectivity and data-driven decision-making."

Tanya Trojansky is global solutions engineer visualisation at Murrelektronik

www.murrelektronik.uk/gb/