Digital Twin: A 3D Model Supporting the Entire Machine Lifecycle
Machines and plants are becoming increasingly complex, and so is the need for information during operation. Where is a particular machine component located? Where is the corresponding manual? Which spare part is required at this point? Our digital customer platform already gathers all relevant machine data and documents in one place. The digital twin, however, goes one step further: it links this information to a 3D model of the machine itself and places real-time data, instructions, processes, and other documents exactly where they are relevant.
For large-scale plants in particular, this direct connection makes a noticeable difference for both the machine builder and its end customers. During maintenance or in the event of a malfunction, machine operators find the right information faster, reducing the number of recurring inquiries machine builders receive.
In addition, the machine becomes tangible as early as the sales stage, and the model remains just as useful after the purchase, for example by showing the service team immediately which component is affected by an alarm.
In Operation: Targeted Access to Information
Once a machine has been delivered, it enters the longest phase of its lifecycle. From then on, operators constantly need information, whether they are checking current machine data or carrying out maintenance. This is exactly where the digital twin proves its value in day-to-day operations.
Hotspots lie at the heart of this functionality. The 3D model serves as an interactive map of the machine, with markers positioned at key locations such as a gearbox, a pump, or a filter. A single click provides access to all information associated with that component.
Which information is displayed can be configured individually for each hotspot. This can range from current readings at that location, such as temperature or fill level, to operating manuals, active alarms, and maintenance forms that guide users through each step. For larger plants comprising several machines, sub-assets additionally allow separate data streams to be defined for each individual machine.
In addition, each hotspot is assigned its own QR code, which can be affixed to the corresponding location on the physical machine. This bridges the gap between the 3D model and the machine on the shop floor, providing operators with an additional point of access. When maintenance is due, the on-site team simply scans the code on the component and instantly has the relevant information on their smartphone.
In Sales: Presenting Complex Machines with Clarity
The benefits, however, are not limited to the period after delivery. For complex machines in particular, prospects often struggle to form a complete picture from drawings and datasheets alone. The digital twin makes the machine tangible during the sales process, allowing customers to explore it interactively from every angle and gain a realistic impression of the machine.
For machine builders, this translates into a clear advantage in sales. The design and functionality of the machine can be explained in a highly visual way, discussions become more focused, and purchasing decisions rest on a sound basis. An offering that enables customers to experience the machine digitally also sets itself apart from the competition.
Renderings complement this by generating machine images from individual components for purposes such as presentations. Finally, because the digital twin remains in use beyond the purchase, it lays the foundation for a long-term customer relationship from the very first conversation.
In Customer Service: From Service Process to Service Offering
The digital twin also proves to be a valuable tool for the service department, since real-time data and alarms are tied directly to the component they relate to. As a result, technicians can pinpoint the source of an alarm on the machine the moment it is triggered. This makes it possible to plan service calls more precisely. At the same time, data-driven services become easier for customers to grasp, which in turn makes them easier to sell.
The Value for Machine Builders
Taken together, these three areas highlight the defining strength of the digital twin: it adds a spatial dimension to the customer platform. Machine data and documents remain centrally accessible while also being linked precisely to the point on the machine where they are relevant.
For machine builders, this generates value across the entire machine lifecycle. In sales, complex machines can be presented in a compelling and transparent manner. In operation, digital hotspots resolve a wide range of questions and noticeably reduce the service team’s workload. Should an alarm still be triggered or a spare part be required, operators and service technicians work from the same point of reference in the model, which significantly streamlines coordination. As the digital twin becomes an integral part of customers’ daily operations, the machine builder remains a visible partner long after delivery.
Experience the Digital Twin Live
In a personal meeting, we will demonstrate the digital twin live, address any questions you may have, and share further insights into how machine builders and their customers can benefit from it.
For step-by-step guidance on setting up a digital twin, please refer to our help center article: Digital Twin
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