Digital Twin for Feeding, Conveying, Rejecting and Assembly of Caps Using FESTO Meclab Modules

Digital twins (DT) are virtual replicas of physical systems that enable real-time simulation, monitoring, and optimization, enhancing accuracy, efficiency, and decision-making. However, accessibility to digital technologies poses a challenge to their implementation. This work develops a DT for a process involving the feeding, transportation, rejecting, and assembly of metal and plastic caps using FESTO MecLab modules. The modules are modeled in 3D using Inventor. Communication between the physical asset and the virtual asset via OPC DA is managed through FluidSIM. The process logic is implemented in CoDeSys, and the DT is developed in MATLAB, following the guidelines of the Digital Twin Consortium (DTC). The control architecture, based on the ISA 95 standard, is evaluated using the Industrie 4.0 Toolbox from the Association of German Mechanical and Plant Engineering (VDMA, by its German acronym).