




































    

 Academic Journal of Science, Engineering and Technology 

Vol.7, Issue 4; July - August 2022; 

1252 Columbia Rd NW, Washington DC, United States 

https://topjournals.org/index.php/AJSET/index; mail: topacademicjournals@gmail.com 

  

 

 

1 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

NAVIGATING THE DIGITAL FRONTIER: UNLEASHING THE POTENTIAL OF 

DIGITAL TWIN TECHNOLOGY 

 

Ming Liang Zhang, Wei Xing Chen, Yu Xin Guo and Hui Min Wu 

Xi'an Research Inst. of Hi-Tech, Xi’an, China 

 

Abstract: Digital twin technology has emerged as a key means to promote intellectualization and digitalization 

in various fields. It is a technical means based on simulation, with the integration of data and model as the core. 

This paper provides a brief overview of the development history and definition of digital twin, proposes that 

digital twin consists of three basic components: physical layer, transmission layer, and virtual layer, and explains 

the key technologies involved such as sensing and monitoring, complex system modeling, and big data analysis. 

The current research on digital twins is summarized, including theory, data, and technology. Typical applications 

of digital twins in industrial manufacturing, smart cities, aerospace, and other aspects are described. Finally, the 

paper looks forward to the development trends of digital twin technology. 

Digital twin technology offers real-time, reusable, and intelligent solutions for product design, experimental data 

collection, experimental result analysis, and prediction. The advantages of digital twin technology have been 

recognized by many countries, including the United States, the United Kingdom, and China. As digital twin 

technology continues to evolve, it is expected to play an increasingly important role in the construction of digital 

China and the advancement of other countries towards digitalization. This paper highlights the need for further 

research on the key technologies of digital twin to promote its application and development. 

Keywords: Digital twin, simulation, data integration, real-time, reusable, intelligent, sensing, monitoring, 

complex system modeling, big data analysis, industrial manufacturing, smart cities, aerospace, development 

trends. 

 

 

1. Introduction  

With the continuous advancement of intelligence and digitalization in various fields, digital twin technology has 

received more and more attention. The United States takes digital twins as the main carrier, focusing on military 

and large-scale equipment and other fields; The UK has set up a digital construction center with plans to build a 

national twin; In 2020, China also wrote digital twins into the "14th FiveYear Plan", which became an important 

part of the construction of digital China. As an important technical means to improve production efficiency, digital 

twin has great advantages in product design, experimental data collection, experimental result analysis and 

prediction, etc., and the research on key technologies of digital twin to promote its application and development 

will effectively promote China's digital process.  

2. The evolution of digital twins  

At the beginning of the twentieth century in the aerospace field, due to high manufacturing costs, complex design, 

inconvenient flight test data collection and other problems, in the process of product design and development, the 

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 Academic Journal of Science, Engineering and Technology 

Vol.7, Issue 4; July - August 2022; 

1252 Columbia Rd NW, Washington DC, United States 

https://topjournals.org/index.php/AJSET/index; mail: topacademicjournals@gmail.com 

  

 

 

2 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

concept of "simulation" appeared. Early simulations focused on physical mapping of entities to describe the 

internal characteristics or environmental conditions of the system. With the rapid development of computer 

technology, simulation technology has gradually developed into all-digital simulation based on mathematical 

models. However, there may be a large modeling error or inability to model the physical object in the all-digital 

simulation, so it is tried to connect the physical object in a certain part of the simulation loop and test it under the 

conditions that meet the overall system performance, resulting in semi-physical simulation. In the early eighties, 

"Virtual reality" technology was proposed, which refers to simulating the environment through computers, so that 

participants can have different sensory experiences and understand the objective world from the virtual 

environment. Due to the interactivity and realism of virtual reality technology, simulation technology has been 

greatly developed.   

With the continuous maturity of a new generation of information technology and its deep integration with 

simulation technology, digital twins have emerged. In 2002, Professor Michael Grieves of the University of 

Michigan introduced two systems, real and virtual, when demonstrating product lifecycle management [1], which 

laid the foundation for the emergence of digital twins. Subsequently, Professor Grieves proposed the concept of 

"digital representation of physical products in physical space". In 2010, the term "Digital Twin" was officially 

proposed in NASA's technical report and defined as "the simulation process of a system or aircraft that integrates 

multiple physical quantities, multiple scales, and multiple probabilities" [2]. In 2012, NASA and AFRL defined a 

digital twin for an aircraft as an integrated multiphysics, multiscale, probabilistic simulation model for an aircraft 

or system that utilizes the best available physical models. Updated sensor data and historical data, etc., to reflect 

the state of the flight entity corresponding to the model [3]. As an important tool to improve efficiency, digital twin 

can effectively promote the integration and development of digital economy and real economy.  

3. The basic components of a digital twin  

According to the different definitions of digital twin, the composition of common digital twin systems is proposed 

as shown in Figure 1, which is mainly divided into physical layer, transport layer and virtual layer.  

  
Figure 1: Basic components of the digital twin system  

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3.1. Physical layer  

The physical layer consists primarily of modeled objects and sensing systems in physical space. Modeling objects 

mainly include entities, various equipment, and operating environments; The sensing system mainly relies on 

various sensors to perceive and measure the operating state of the modeled object, and at the same time monitor 

the operating environment and collect data in real time.  

The physical layer involves sensing and monitoring technology [4]. In a complete digital twin system, the 

acquisition of the operating environment and the state data of the digital twin components itself is an important 

part of the accurate mapping and real-time interaction between all elements, all states and the whole process 

between physical objects and their digital twin systems. In order to establish a comprehensive IoT perception 

system and achieve accurate monitoring of the operation situation of physical objects, perception technology 

needs to rely on more accurate physical measurement technology, and also need to consider the synergy between 

the perceived data On the surface or inside the system structure, a distributed sensor network is used to determine 

the spatial location and unique identification of the target to ensure that the equipment is trusted and controllable  

3.2. Transport layer  

The transport layer is the bridge that connects the physical layer and the virtual layer. The transport layer transmits 

the physical operation data obtained by the sensing system to the virtual layer, realizing real-time mapping from 

the physical layer to the virtual layer [6]; At the same time, the control instructions issued by the virtual layer are 

transmitted to the physical layer, thereby intervening in the operation of the entity, so that a two-way data flow is 

formed between the physical layer and the virtual layer.   

The creation and control of digital twins are based on data collected in real time, so the system needs to have 

faster information transmission speed and shorter latency. It can achieve high bandwidth, low latency, support 

distributed information collection, and have high security and high reliability. With the help of the Internet of 

Things, blockchain, 5G, quantum communication and other means, the information of the physical layer is 

transmitted quickly and accurately, and the security and reliability of information need to be guaranteed.  

3.3. Virtual layer  

The virtual layer is the core part of the digital twin system, which is the mapping of the physical layer in the 

digital space, containing a model as close as possible to the physical object and synchronized with the physical 

layer. The implementation of digital twin should be driven by data and supported by the model, and the twin 

model is a true description of the physical layer entity, mapping the physical layer from different dimensions and 

different aspects, so that the entity state is reflected in the virtual space. The twin data comes from real-time 

monitoring data and historical data at the physical layer, and is processed to drive the twin model.   

The establishment of virtual layer model mainly applies to complex system modeling technology. Digital twin 

model includes visual model and mathematical model, by studying the structural composition and assembly 

relationship of physical entities, 3D MAX, SolidWorks and other threedimensional modeling tools can be used 

to establish the corresponding models of each part, and synthesize after verification to obtain a visual model 

reflecting the overall appearance, structure, size and other information of the physical object [7]. Since the 

mathematical model has the characteristics of involving many disciplines, diverse forms, many types, and large 

quantities, it can be modeled according to the product composition relationship of different subsystems [8]. The 

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 Academic Journal of Science, Engineering and Technology 

Vol.7, Issue 4; July - August 2022; 

1252 Columbia Rd NW, Washington DC, United States 

https://topjournals.org/index.php/AJSET/index; mail: topacademicjournals@gmail.com 

  

 

 

4 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

connection and motion law of each subsystem of the physical object were analyzed, the corresponding 

mathematical model was abstracted by means of mechanism modeling or parameter estimation, and simulation 

tools such as MATLAB/Simulink and Modelica were used to carry out simulation research under different 

conditions and parameters [9]. In addition, the digital twin system can be more closely related to the actual system 

by modeling the environment and analyzing the operation status of the digital twin under different conditions [10].   

The data received by the virtual layer usually has the characteristics of multiple types, large volume, and high 

application value. By establishing a corresponding database to store data, and using big data analysis technology, 

real-time screening and processing of data, fully activating and releasing data value, and exploring the 

interrelationship between different data to achieve the purpose of diagnosis, prediction and decision-making [11].  

4. Current state of digital twin research  

At present, digital twins mainly include theory, data, technology, etc., as shown in Figure 2.  

  
Figure 2: Digital twin research direction  

In terms of theoretical research, Zhuang Cunbo [12] reviewed the background and concept of digital twin, and 

introduced the specific connotation of product digital twin. Tao Fei [13] aimed at the establishment of digital twin 

models, put forward the construction criterion of "four modernizations, four can be used in eight ways" of digital 

twin models, and carried out research and practice on the construction theory of digital twin workshop models. 

Jia Shiqi [14] summarized the current development of digital twin technology, summarized its practical results and 

future application directions, and looked forward to the needs and prospects of digital twin standardization 

according to the current standardization process. Zhou Junhua [15] analyzed the development process of digital 

twin technology, pointed out the necessity of applying digital twin technology to weapon system research and 

practice, and elaborated its concept and composition. Zhang Dawei [16] introduced the application of digital twin 

technology in equipment life cycle cost management, and pointed out the existing problems and solutions, so as 

to provide reference for improving the cost efficiency of equipment.   

In terms of technical analysis, Liu Yang [6] analyzed the connotation, development context and significance of 

industrial digital twin, focused on the development direction of industrial digital twin, and put forward several 

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Vol.7, Issue 4; July - August 2022; 

1252 Columbia Rd NW, Washington DC, United States 

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5 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

suggestions on its development. Jiang Haifan [17] put forward the concept of digital twin evolution model, and 

gave the application methods, key technologies and working platforms of the three evolution stages of digital 

twin. Wang Huixia [18] analyzed the main differences between digital twin technology and simulation technology, 

refined the key technologies involved in digital twin, and designed the basic framework and application mode of 

digital twin of launch vehicle control system. Lu Qing [19] discussed the application of digital twin technology in 

aircraft architecture model design, multi-model architecture integration, model parameter identification and 

verification, and provided important guidance and technical support for the development of aircraft models and 

integration tests. Wang Wei [20] analyzed the development and value of digital twin, elaborated the basic 

characteristics and architecture of digital twin, introduced the key technologies of digital twin on this basis, and 

finally looked forward to its development prospect. Wu Yan [21] based on digital twin technology, sorted out the 

concept of digital twin, and discussed digital twin technology in manufacturing.   

In terms of data processing, Zhang Suming [3] introduced a rocket test and launch process health management 

system based on digital twin technology, and carried out design optimization and performance analysis, realizing 

data analysis, diagnosis collaboration, and fault handling decision support. Fan Rui [22] discussed the application 

of digital twin technology in data monitoring of intelligent production systems, and discussed how to achieve an 

efficient combination of production site and production management. In order to solve the problems encountered 

in the modeling and data acquisition of digital twin workshop, Zhou Shuaichang [23] proposed to use the half-side 

folding algorithm to make the complex three-dimensional model lightweight, and the improved fuzzy C-means 

algorithm to improve the accuracy of the data.  

5. Typical applications of digital twin technology  

5.1. Application of digital twins in industrial manufacturing  

Siemens has been closely following the development trend of Industry 4.0 and intelligent manufacturing in 

Germany, and has been committed to the development and application of digital twin technology in recent years, 

and has integrated digital twin technology into its digital strategy in the past two years. Siemens uses digital twin 

technology to digitally design, optimize and validate production processes, modify plant layouts, select 

production equipment, optimize production processes, and more. The automation system is verified through 

virtual commissioning technology, enabling it to be commissioned quickly and efficiently on site. Control the 

physical world in the virtual world, so that the entire workshop can achieve complete integration, so as to achieve 

efficient and reliable production; Complete production planning, production execution and quality inspection 

through the manufacturing operation management system; With Mindsphere, all machines and equipment can be 

monitored in real time to analyze and evaluate actual production. Through analysis and forecasting, we can drive 

continuous improvement of actual production and products, thereby shortening the product design optimization 

cycle.   

In the application of machine tools, with the help of digital twin technology, enterprises can complete simulation 

and verification from cutting to maintenance and fault diagnosis in the digital world in advance during the 

development stage. It can not only save the debugging cost of mature models and extend the life cycle, but also 

improve the research and development efficiency of new models and reduce trial and error costs. For machine 

tool end users, digital twin software can be used to test cut and proofing parts without physical prototyping and 

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6 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

environmental construction, which can significantly reduce the risk and cost of the machining process. In addition, 

users can also use the digital twin to train personnel and effectively avoid the risk of machine collisions caused 

by insufficient personnel experience by simulating the operating environment.  

5.2. Application of digital twins in smart cities  

Urban digital twin is a technical means of simulating modeling and interactive control of the whole life cycle 

process of urban physical entities through the digital virtual mapping of the city, with the help of historical data, 

real-time data, spatial data and algorithm models, etc., which can express and present all elements of physical 

objects, relationships, activities, etc. in the urban physical space and social space in the digital space, so as to 

realize the comprehensive perception and precise control of the city and promote the intelligent and digital 

development of the city [24]。   

During the construction of Xiong'an New Area, it proposed to "adhere to the synchronous planning and 

synchronous construction of digital city and real city", based on the theory of urban complex adaptation system, 

to build a digital twin of the city, so that the physical city and the digital city can be connected in real time and 

dynamic feedback, constantly track and identify the changes of the city, so that the "hidden order" of the city can 

be made visible, so as to better follow the law of urban development [25]. All elements of Xiong'an New Area will 

be built synchronously in the digital city according to the construction sequence, and updated with the 

development of the city, and jointly iterated, which is an ecosystem that can evolve. The biggest innovation of 

digital twin cities lies in the fact that physical cities and digital cities can coexist and grow together, and the virtual 

and real can be integrated.   

The digital twin technology is introduced into the urban flood disaster assessment and early warning system, and 

realizes the visual integration of the city by establishing an intelligent perception system covering all elements of 

urban flood disaster, integrating real-time data such as land, water system, and transportation. Use data to realize 

the dynamic evolution of urban digital twin, drive urban flood disaster scenario simulation analysis and decision-

making system, predict the development trend of flood disaster through intelligent algorithms, and automatically 

issue early warning signals when necessary. The optimized system solves the problems of insufficient perception 

and dynamic response ability of the original system and poor real-time decision-making, and integrates the 

functions of urban real-time rain monitoring, flood disaster assessment, disaster prevention simulation and early 

warning [26].   

Digital twin library refers to the use of physical model data and multi-scale simulation technology to 

comprehensively model the physical entities of the library in the virtual space in order to complete the iterative 

optimization of all elements, holographic intelligent monitoring, and global intelligent construction. Through the 

whole process of data mining, operation monitoring and integrated analysis of the physical entities of the library, 

a new model library that can realize intelligent interaction between virtual and real is built. Its essence is to build 

the digital expression of the physical entity of the library, realize the extension of the full life cycle service of the 

library, carry out virtual and real interaction, tracking and analysis and two-way real-time mapping in the virtual 

information space, and maintain the synchronous update of data transformation, and accurately optimize the 

physical services, facilities and resources of the library [27].  

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7 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

5.3. Application of digital twins in aerospace  

In the design and development, manufacturing and assembly, operation and maintenance of aircraft, the 

introduction of digital twin technology can effectively shorten the development cycle and significantly reduce 

costs. By establishing a digital twin of the aircraft, the product testing and verification is completed virtually in 

the digital space, and defects are found in the design stage and the design is improved in time to avoid waste 

caused by repeated modifications [28]; In the actual production and manufacturing, the processing status of each 

part can be tracked in real time, and the existing manufacturing process can be continuously optimized through 

reasonable allocation of resources to reduce downtime; In the maintenance stage, sensors are used to monitor the 

status of the aircraft in real time, reflect the real flight conditions, and can realize the dynamic update of the model 

by combining intelligent algorithms, improve the prediction ability, and can also be used to diagnose the cause of 

abnormal situations and evaluate after the occurrence of failures [29].   

The digital twin satellite is a collection of digital models with the same origin, data sharing, coevolution, real-

time interaction, synchronization between heaven and earth, and extended survival of the physical satellite [30]. 

The digital twin satellite can reflect the formation process, real-time status and behavior of the physical satellite, 

and predict, evaluate and optimize the physical satellite in the digital space. It is the twin asset and efficiency 

multiplier of the whole life cycle and the whole value chain of the satellite product. On the basis of realizing the 

digital twin function of general aircraft, the digital twin satellite can also optimize the shape parameters and 

deployment process of the satellite solar wing using the entity data; And the use of digital twins for ground thermal 

test can further save the resources on the satellite [31].  

The application of digital twins to rocket testing and launch processes can effectively improve the reliability of 

rocket launches. In the ground test stage, the ground digital twin system monitors and interprets the data of each 

instrument during the test, and at the same time identifies the abnormal data to assist the profession Personnel 

make decisions; During the ignition take-off phase, the engine thrust status diagnosis is carried out, and the takeoff 

process will be performed only after the digital twin on the arrow and the ground judge that the rocket starts 

normally; In the rocket flight phase, the digital twin system regularly receives the data transmitted by the telemetry 

system, carries out real-time simulation prediction, accelerates the determination of alternative solutions when a 

fault is detected, and issues control instructions to the rocket to minimize the occurrence of failure [32].  

6. Summary  

With the continuous deepening of the research on digital twins by scholars from all aspects, the technology has 

made rapid development in recent years. However, in the application process of digital twins, there are still 

problems such as the lack of unified standards, the lack of interdisciplinary integrated design platform, and the 

need to further improve the application of core technologies. Therefore, most of the current work is concentrated 

in the theoretical research and experimental verification stage. Nevertheless, because of the great advantages of 

digital twins such as virtual-reality mapping, real-time synchronization, symbiosis and evolution, it is of great 

significance to study its key technologies, break through the difficulties encountered one by one, and promote its 

application in manufacturing, aerospace, urban management, smart medical and other fields to promote China's 

digital process.  

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8 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

|  https://topjournals.org/index.php/AJSET 

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10 | A c a d e m i c  J o u r n a l  o f  S c i e n c e ,  E n g i n e e r i n g  a n d  T e c h n o l o g y  

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