Leveraging Virtual Commissioning for Digital Twins: An example case

Virtual commissioning (VC) and digital twins (DT) are pivotal technologies in the Industry 4.0 (I4.0) landscape. However, their integration remains underexplored in the literature. This study proposes a structured methodology for optimising production line design and operation by integrating VC and DT. The proposed approach leverages two VC methodologies—Software-in-the-Loop (SIL) and Hardware-in-the-Loop (HIL)—to facilitate algorithm testing in both simulated and real-world environments. Bidirectional, real-time data exchange between virtual and physical models is established using OPC UA and RTDE protocols, creating a digital shadow that continuously updates to reflect the active system. The proposed framework promotes lifecycle-wide use of simulation models, enabling seamless reuse from VC to DT, while demonstrating the interactive potential of these technologies. Furthermore, the study highlights the advantages for companies in adopting both VC and DT to enhance operational performance.