Custom Digital Twins
PRM.DEV builds digital twins — accurate virtual replicas of products and processes. They ingest real-time data, run simulations, and support decision-making across the full lifecycle within Industry 4.0.
We create digital solutions as a layer between assets — sensors, drives, and software. This improves observability, speeds up debugging, and makes it easier to introduce AI use cases in industrial automation, smart buildings, and smart cities.
We create digital solutions as a layer between assets — sensors, drives, and software. This improves observability, speeds up debugging, and makes it easier to introduce AI use cases in industrial automation, smart buildings, and smart cities.
How it works
A physical asset (for example, a pump) streams telemetry: current, voltage, temperature, vibration.
Data flows into the digital twin model and to upper layers: SCADA, cloud, web/mobile apps.
Engineers run simulations, analyse behaviour, and tune parameters without touching the hardware.
Outcome: more accurate forecasts, less downtime, and faster changes to settings and logic.
Digital twin vs simulation and IoT
- Continuity
Instead of a one-time simulation, a digital twin is a continuous model that runs multiple scenarios in parallel and synchronises with live data. - Not instead of IoT — above IoT
IoT collects telemetry and controls devices, while a digital twin consolidates data, applies rules and AI/ML models, and manages assets at the system level.
Technologies and standards
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Platforms and frameworks
- Eclipse Ditto — managing digital representations of devices
- Azure Digital Twins — digital twins within the Azure ecosystem
- FA³ST (FAAAST) — an AAS implementation for industry
- Shifu — device and service abstraction for DT/IoT
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Information models and specifications
- Asset Administration Shell (AAS) for describing assets
- Web of Things (W3C WoT) — unifying device-to-service interaction
- Digital Twin Definition Language (DTDL) — entity modelling
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NVIDIA Omniverse
We use NVIDIA Omniverse Cloud and Omniverse Enterprise on NVIDIA OVX for accurate physics, collaboration, and real-time rendering. This enables consistent data, photorealistic scenes, and scenario simulations.
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Unity Industry
We use Unity Industry for interactive 3D twins with rapid iteration. We integrate data from BIM/CAD, PLM, and IIoT and support 20+ platforms (Windows, iOS, Android, and more) — from pilots to large-scale rollouts.
Where digital twins help
- Early design stagesVirtual prototypes of devices and subsystems shorten cycles and reduce errors.
- Performance optimisationAssess efficiency, consumption, thermal behaviour, and control logic.
- SafetyModel аварийные scenarios and validate protections without risk to people or equipment.
- ManufacturingOptimise layouts, routes, tooling, and takt time; reduce costs.
Industries and use cases
Digital twin levels:
- Component/part: wear, lifetime, maintenance прогноз
- Asset/product: unit efficiency, меньше downtime, режим optimisation (e.g., raw material heating)
- System/plant: asset interaction, balancing, wear minimisation, new optimisation opportunities
- Process/enterprise: end-to-end coordination, input tuning, KPI control without остановки
- Virtual production line — equipment, robots, logistics in one environment
- Scenario modelling — from incoming components to final assembly
- Virtual testing — compatibility, quality, and performance parameters
- Failure scenarios — rehearsing faults and system responses
- Real-time integration — telemetry vs model comparison, auto-tuning
- Predictive maintenance — condition-based repairs, less downtime
- Takt time optimisation — меньше losses and more reliable delivery dates
A 3D twin runs alongside the converter control system and reflects its state under heavy режимs and harsh conditions.
Challenges: operating near component limits, long-term degradation.
Solution: the twin predicts wear, suggests replacement timing, and корректирует control algorithms.
Solution components:
Challenges: operating near component limits, long-term degradation.
Solution: the twin predicts wear, suggests replacement timing, and корректирует control algorithms.
Solution components:
- Physical system: the real asset
- Digital twin: behaviour model
- Feedback: currents, voltages, temperature, vibration
- Analytics: real vs model comparison, anomaly detection
- Actions: recommendations and automatic adjustments for optimal режим
Digital twins can describe everything—from a pump-and-treatment unit to a full distribution network.
Benefits:
Benefits:
- Planning and cost savings — virtual selection of components and schemes reduces cost and time
- Real-time decisions — monitoring pump efficiency and water quality extends asset lifetime
- Scenarios and resilience — аварий simulation, energy saving, hydraulic survivability under failures
- Predictive alerts — early warnings for dispatchers and автоматические controllers
Ready to accelerate your digital twin rollout? Message us — we’ll help design a solution for your industry.
Our offices
Moscow
Troparyovskaya St., 4, bld. 1, room 6A
Moscow 119602, Russian Federation
Moscow 119602, Russian Federation
Innopolis
Universitetskaya St., 7, room 7
420500, Innopolis, Republic of Tatarstan
420500, Innopolis, Republic of Tatarstan
Contact us to discuss your engineering challenges
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