2025 ASEE Annual Conference & Exposition

Today's manufacturing ecosystems are more complex than ever. With the integration of cutting-edge technology and software capable of transmitting information in real-time, these ecosystems have become increasingly sophisticated. The industry is transitioning from manual operations and execution to fully automated systems. As a result, the concept of Digital Twins (DT) is gaining widespread adoption, with industries aggressively embracing this technology. In this project, we developed a Digital Twin of a conveyor system using FlexSim simulation software, the FlexSim Emulation module, and a Programmable Logic Controller (PLC). The DT incorporates multiple sensors, including a vision sensor, to capture data from the conveyor. The FlexSim simulation software was used to create a 3D virtual model of the conveyor, while the FlexSim Emulation module enabled real-time data transfer between the physical conveyor, sensors, and PLC. When an event occurs on the physical conveyor—such as an object entering or exiting—the sensors detect it and transmit the signal to the emulator. This data is then processed and visualized on the virtual replica. A vision sensor positioned at the center of the conveyor identifies the object's color, which is updated in real-time within the simulation. In case of an unexpected event, the DT can send signals to the physical system to adjust conveyor operations via the PLC. This Digital Twin provides real-time monitoring, enhances remote oversight, and enables better control of the manufacturing ecosystem. For this project, we developed a mini-scale prototype as a testbed with limited functional capabilities. However, the DT is highly scalable and can be expanded for larger systems with enhanced functionality and control mechanisms.