Simulation based Digital Twin Builder

Now is the era of the Digital Twins. Engineering simulation is no longer limited to the product development process. The technologies that support the Internet of Things (IoT) now make it possible to go a step further by integrating simulation with products as they exist and operate in the real world. Complete virtual prototypes of the entire system can be developed to represent a real-time, virtual copy of an actual operating machine that provides insight into individual product performance and maintenance. With digital twins, companies can predict the future and anticipate how changes in design, process, or environment will affect how an asset functions in the real world. Sensors on the machine send data such as temperature, pressure, flow rate, voltage, loading, etc to the digital twin and the twin evolves in step with the machine’s working environment. The digital twin can predict the condition long before the downtime may happen, so the issue can be addressed immediately before they affect system performance, limiting the downtime to save on overall product costs.

Why Need Digital Twins?

What Industries use the Digital Twin?


There are several key components in Digital Twins: Sensors, Data analytics, Controls, a Communication platform, and Machine learning. With digital twins, a lot of information can be collected using sensors data such as Temperature, Velocity, Stress Distribution, and Motion. This allows an accurate virtual replica of the physical system to be built.



ANSYS Twin Builder is a multi-technology platform that allows engineers to create simulation-based digital twins which are digital representations of assets with real-world sensor inputs. With ANSYS Twin Builder, the system can be built quickly and easily since it combines the power of a multidomain systems modeler with extensive 0D application-specific libraries, 3D physics solvers, and reduced-order model (ROM) capabilities. When used together with embedded software development tools, Twin Builder allows the reuse of existing components to quickly create a systems model of your product. To validate the system and ensure expected performance, ANSYS Twin Builder combines multidomain systems simulation capabilities with rapid human-machine interface (HMI) prototyping, systems optimization, and XiL validation tools. To connect the twin model to test or real-time data, ANSYS Twin Builder easily integrates with the industrial internet of things (IoT) platforms and contains runtime deployment options, allowing you to perform predictive maintenance on the physical product.

One of the main building blocks in digital twins is reduced-order modeling (ROM) where its creation can be facilitated using ANSYS Twin Builder. ROM models are high fidelity simplified models which consist of only inputs and outputs. By doing this, a complex system can be converted into a much simple model. Finally, a systems-level model is integrated with these ROM models.


With the rapid expansion of IoT technologies, accurate digital replicas of physical things such as infrastructure, manufacturing equipment, etc now can be realized. This brings significant value through both cost-saving and new revenue streams.