Continued use of virtual commissioning models: A novel approach toward digital twins for automated production systems

Research output: Contribution to journal › Research article › Contributed › peer-review

Contributors

  • Felix Ferle - , Chair of Machine Tools Development and Adaptive Controls, BMW Group (Author)
  • Shengjian Chen - , University of Stuttgart (Author)
  • Alexander M. Kuhn - , BMW Group (Author)
  • Lars Klingel - , University of Stuttgart (Author)
  • Christer Clifford Schenke - , Fraunhofer Institute for Machine Tools and Forming Technology (Author)
  • William Tekouo - , BMW Group (Author)
  • Alexander Verl - , University of Stuttgart (Author)
  • Steffen Ihlenfeldt - , Chair of Machine Tools Development and Adaptive Controls, Fraunhofer Institute for Machine Tools and Forming Technology (Author)

Abstract

Virtual Commissioning (VC) is an increasingly integral practice in the engineering of production systems, evidenced by growing research and industrial adoption. Advancements in VC model fidelity, computational performance, and automated generation are improving the validation of complex production systems and point toward further applicability beyond conventional control software validation. In industrial practice, however, VC models are still confined to their original use. While emerging applications for VC models in the operational phase highlight the potential for model reuse, a structured method for transforming these valuable engineering assets into Digital Twins (DTs) is still absent. This paper addresses this gap through three main contributions: first, by clarifying the VC/DT boundary within production contexts and identifying open research questions; second, by introducing a novel six-phase transformation method; and third, by identifying industrially-derived use cases and their specific requirements. The proposed method adopts the Design Science Research (DSR) methodology to systematically structure the problem space, derive actionable objectives, and design the iterative development process. Initial results include a set of industrial use cases with their corresponding requirements, as well as the exemplary execution of one development cycle. Finally supplemented by a qualitative cost-benefit analysis, this work offers practical guidance for realizing VC-based DTs that support operational tasks in production environments.

Details

Original languageEnglish
Pages (from-to)4609-4626
Number of pages18
JournalInternational Journal of Advanced Manufacturing Technology
Volume142
Issue number9-10
Publication statusPublished - Feb 2026
Peer-reviewedYes

Keywords

Keywords

  • Digital factory, Digital twin, Operational phase, Production planning, Virtual commissioning