{"id":109049,"date":"2025-06-15T12:00:00","date_gmt":"2025-06-15T12:00:00","guid":{"rendered":"https:\/\/industry-science.com\/?post_type=article&p=109049"},"modified":"2025-06-16T22:41:02","modified_gmt":"2025-06-16T20:41:02","slug":"the-core-principles-of-the-digital-twin","status":"publish","type":"article","link":"https:\/\/industry-science.com\/en\/articles\/the-core-principles-of-the-digital-twin\/","title":{"rendered":"The Core Principles of the Digital Twin"},"content":{"rendered":"

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In the past, digital twins were defined as “digital representations of things from the real world” [1]. However, this narrow definition no longer reflects the complexity digital twins in the context of Industry 4.0. The current definition by the VDI expands this view: “A digital twin is much more than a digital copy of a physical object. It forms the basis for a continuous exchange of data between the real and digital worlds. Based on models, algorithms and simulations, properties or behaviors of the object are described and influenced. The concept comprises three core areas: the …<\/div>\n

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Subscription<\/th>\nincluded<\/th>\nPurchase<\/th>\n
without<\/td>\n−<\/td>\n29,00 \u20ac<\/td>\n
Digital<\/td>\n−<\/td>\n27,55 \u20ac<\/td>\n
Expert<\/td>\n✓<\/span><\/td>\n0,00 \u20ac<\/td>\n
Professional<\/td>\n✓<\/span><\/td>\n0,00 \u20ac<\/td>\n
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Systematically Planning Vertical Factories<\/h4>\n
Developing factory types as a foundation for intelligent planning support<\/div>
Nikolaus Kremslehner<\/a> \n \"ORCID<\/a>, Sebastian Schlund<\/a> \n \"ORCID<\/a>, Wilfried Sihn<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n Vertical factories reduce land use and harness the advantages of urban production. However, their multi-story structure significantly increases planning complexity. To counter such effects, this paper presents a typology that combines proven solutions for recurring challenges in the planning and operation of vertical factories. Relevant characteristics were examined using real-world case studies and structured within a morphological framework. This framework was consolidated into factory types that provide guidance for conceptual planning and serve as the foundation for intelligent planning support. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 5 | Pages 68-76 | DOI 10.30844\/I4SE.26.5.6<\/a><\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"AI-Based\n <\/picture>\n <\/div>\n
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AI-Based Building Inspection for Large Structures<\/h4>\n
A new approach to construction progress monitoring<\/div>
Jan Sender<\/a> \n \"ORCID<\/a>, Konrad Jagusch<\/a> \n \"ORCID<\/a>, Michael Geist<\/a> \n \"ORCID<\/a>, David Jericho<\/a> \n \"ORCID<\/a>, Christian Scharr<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n Monitoring construction progress, as required in the one-off production of large structures, is very time- and labor-intensive due to a high level of complexity and individuality. The goal of this article is to develop a sensor-based approach for capturing and evaluating multiple inspection characteristics. The use of machine learning models to detect objects and derive relevant information forms the basis for linking current condition to construction schedule. This enables a significant increase in efficiency during construction progress monitoring and a well-founded assessment of progress. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 5 | Pages 78-84 | DOI 10.30844\/I4SE.26.5.9<\/a><\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"Digital\n <\/picture>\n <\/div>\n
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Digital Twin Technology and Architecture<\/h4>\n
A synthesis of concept and practice<\/div>
Arka Mukherjee<\/a> \n \"ORCID<\/a>, Shibaji Chandra<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n
\n\t\t\t \n\t\t\t <\/div>Digital twins are a key enabling technology of the fourth industrial revolution, integrating physical systems with their digital counterparts to create intelligent, data-driven environments. This conceptual\/practice-oriented paper examines how to establish a modern architectural framework for digital twins leverages modern tech-stack like IoT, Data Fabric, AI\/ML, seamless integration and enterprise grade security. The paper is grounded in an abundance of literature by leading vendors and analysts in space. It offers a comparative study of different vendors implementing the solution stack in the proposed architecture. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 114-122<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"Site\n <\/picture>\n <\/div>\n
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Site Assessment for Flexible Intralogistics in Brownfield Sites<\/h4>\n
Innovative decision support in practice<\/div>
Jolanda Schierbaum<\/a>, Carsten Feldmann<\/a>, Lars Renhof<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
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\n\t\t\t \n\t\t\t <\/div>Due to its dynamic environment, space planning in intralogistics is not a one-time task but a recurring decision-making process subject to numerous constraints imposed by existing infrastructure. Decisions are often based on incomplete data, resulting in a high risk of poor planning decisions and inefficient use of space. This paper presents a practice-oriented process model for space evaluation in brownfield projects. The proposed approach improves the standardization and consistency of space evaluation and promotes best practices among all stakeholders. By supporting systematic decision-making, the process model contributes to optimized planning and resource allocation, thereby reducing risks and avoiding costly implementation errors.The process model is demonstrated through a case study conducted at a commercial vehicle manufacturer. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 124-133<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"Developing\n <\/picture>\n <\/div>\n
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Developing Virtual Reality in Learning Contexts<\/h4>\n
Navigating efficiency, content relevance and scalability<\/div>
Stella Kanatouri<\/a> \n \"ORCID<\/a>, Oliver Sosna<\/a> \n \"ORCID<\/a>, Alexander Kulik<\/a>, Sina C. Truckenbrodt<\/a> \n \"ORCID<\/a>, Friederike Klan<\/a> \n \"ORCID<\/a>, Christian Erfurth<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n While virtual reality can facilitate hands-on learning, its development faces barriers, including high costs and time demands and scalability challenges. This article presents two case studies that illustrate strategies for overcoming such barriers when training the next generation of skilled workers in environmental technologies. By examining approaches for streamlining development and increasing content relevance and scalability, we highlight lessons learned for future practice. We conclude by envisioning a future in which educational institutions can flexibly and cost-effectively prototype virtual reality in learning contexts, ensuring alignment with curricular goals and learners\u2019 needs. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | Edition 3 | Pages 26-34 | DOI 10.30844\/I4SE.26.3.3<\/a><\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"Immersive\n <\/picture>\n <\/div>\n
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Immersive Human Digital Twins for Industry 4.0<\/h4>\n
Supporting adaptive human-centric production by integrating cognitive and physical states<\/div>
Tajbeed A. Chowdhury<\/a> \n \"ORCID<\/a>, Martina Lehser<\/a> \n \"ORCID<\/a>, Eric Wagner<\/a> \n \"ORCID<\/a>, Paul Motzki<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n The rapid advancement of immersive technologies has created new opportunities to transform human-machine collaboration in industry. This paper presents an immersive platform with a digital twin that combines both physical and cognitive characteristics of human dynamics. By integrating multimodal sensing, human biomechanics, and cognitive state into digital twin technology, the proposed system enhances operational safety and ensures better ergonomics. The main argument is that human digital twins are not only desirable but essential for next-generation industrial systems. We discuss the limitations of existing human modeling approaches, outline the conceptual foundations of human digital twins, and demonstrate their industrial relevance across safety, productivity, ergonomics and sustainability. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 6-13 | DOI 10.30844\/I4SE.26.3.1<\/a><\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n<\/div>\n\n","protected":false},"excerpt":{"rendered":"

The digital twin [DT] is considered a key technology of Industry 4.0. Its basic concept is now being successfully applied in practice, as demonstrated by the commissioning of Mercedes’ Factory56 in 2022. New identification technologies, tracking systems and communication solutions faciliate new ways of controlling production and managing material flows, particularly at the shop floor level. With precise technical data permanently available not only for products, but also for material availability and order fulfillment status, production processes can be managed more dynamically and efficiently. This is precisely where the concept of the DT comes into play, enabling the immediate use and evaluation of this data.Its relevance continues to grow, especially in the context of make-to-order production, the rising variety of product configurations, and the globalization of production and supply networks. This article introduces the basic concept of the DT and illustrates how it connects to the Smart Factory.<\/p>\n","protected":false},"featured_media":108917,"menu_order":0,"template":"","categories":[79167,79298],"tags":[79631,79671],"product_cat":[79304],"topic":[67838,68760],"technology":[67599,67717],"knowhow":[],"industry":[],"writer":[83649],"content-type":[],"potential":[],"solution":[],"glossary":[],"class_list":["post-109049","article","type-article","status-publish","has-post-thumbnail","category-design-en","category-typeset","tag-digitaler-zwilling-en","tag-smart-factory-en","product_cat-articles","topic-digital-twin","topic-factory-design","technology-analytics-en","technology-simulation-en","writer-wilmjakob-herlyn-en","product","first","instock","downloadable","virtual","sold-individually","taxable","purchasable","product-type-article"],"uagb_featured_image_src":{"full":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991.webp",1400,788,false],"thumbnail":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-150x150.webp",150,150,true],"medium":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-666x375.webp",666,375,true],"medium_large":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-768x432.webp",768,432,true],"large":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-1024x576.webp",1020,574,true],"front-page-entry":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-1032x320.webp",1032,320,true],"post-entry":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-764x376.webp",764,376,true],"post-teaser":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-392x320.webp",392,320,true],"post-teaser-mobile":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-608x496.webp",608,496,true],"post-custom-size":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-640x325.webp",640,325,true],"whitepaper-teaser":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-274x376.webp",274,376,true],"card-big":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-514x292.webp",514,292,true],"card-portrait":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-320x440.webp",320,440,true],"card-big-company":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-514x289.webp",514,289,true],"gp-listing":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-196x180.webp",196,180,true],"1536x1536":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991.webp",1400,788,false],"2048x2048":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991.webp",1400,788,false],"woocommerce_thumbnail":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-510x510.webp",510,510,true],"woocommerce_single":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-510x287.webp",510,287,true],"woocommerce_gallery_thumbnail":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-100x100.webp",100,100,true],"dgwt-wcas-product-suggestion":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/06\/Herlyn-AdobeStock_1376863991-64x36.webp",64,36,true]},"uagb_author_info":{"display_name":"Malou Baumann","author_link":"https:\/\/industry-science.com\/en\/author\/"},"uagb_comment_info":0,"uagb_excerpt":"The digital twin [DT] is considered a key technology of Industry 4.0. Its basic concept is now being successfully applied in practice, as demonstrated by the commissioning of Mercedes' Factory56 in 2022. New identification technologies, tracking systems and communication solutions faciliate new ways of controlling production and managing material flows, particularly at the shop floor…","_links":{"self":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/article\/109049","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/article"}],"about":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/types\/article"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/media\/108917"}],"wp:attachment":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/media?parent=109049"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/categories?post=109049"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/tags?post=109049"},{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/product_cat?post=109049"},{"taxonomy":"topic","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/topic?post=109049"},{"taxonomy":"technology","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/technology?post=109049"},{"taxonomy":"knowhow","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/knowhow?post=109049"},{"taxonomy":"industry","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/industry?post=109049"},{"taxonomy":"writer","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/writer?post=109049"},{"taxonomy":"content-type","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/content-type?post=109049"},{"taxonomy":"potential","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/potential?post=109049"},{"taxonomy":"solution","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/solution?post=109049"},{"taxonomy":"glossary","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/glossary?post=109049"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}