Author: Dr. Rajesh Verma,
ABSTRACT:The integration of Digital Twin technology into real-time manufacturing process control represents a paradigm shift in the industrial sector, enabling virtual replicas of physical systems to provide predictive insights, operational optimization, and enhanced decision-making. By establishing a continuous data loop between the physical and virtual environments, manufacturers can achieve higher levels of precision, productivity, and adaptability. This paper explores the architecture, working principles, benefits, challenges, and future directions of Digital Twin technology, with particular emphasis on its application in real-time manufacturing environments. The study examines key enablers such as IoT sensors, cloud computing, artificial intelligence, and machine learning for real-time monitoring and control. Additionally, a comparative table illustrates differences between conventional monitoring systems and Digital Twin-enabled manufacturing. The paper concludes that Digital Twin technology not only improves operational efficiency but also accelerates innovation cycles and resilience in smart manufacturing ecosystems.
Keywords — Digital Twin, Real-Time Control, Manufacturing, Industry 4.0, Predictive Maintenance
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