Integration of Digital Twin Frameworks in Cyber-Physical Systems for Enhancing Predictive Maintenance and Reducing System Downtime through Real-Time Sensor Data Fusion and Anomaly Forecasting
Year: 2025
Type: article
Abstract: Cyber-Physical Systems (CPS) are rapidly transforming industrial operations by bridging the gap between physical assets and computational intelligence. However, one of the critical challenges in CPS is ensuring high system reliability and minimizing unplanned downtime caused by equipment failures. To address this, the integration of Digital Twin frameworks has emerged as a transformative solution, enabling real-time monitoring, simulation, and optimization of complex physical processes. This study focuses on the development and deployment of Digital Twin architectures in CPS for enhancing predictive maintenance and reducing system downtime. By leveraging real-time sensor data fusion, the Digital Twin continuously mirrors the physical system, capturing dynamic states and operational conditions. Advanced anomaly forecasting algorithms are integrated into the framework to detect subtle deviations and predict potential failures before they escalate into critical breakdowns. The proposed approach not only improves asset longevity but also ensures cost savings by minimizing unnecessary maintenance interventions. Moreover, the interoperability of Digital Twins within CPS environments fosters adaptive decision-making and enhances system resilience against uncertainties. The integration of artificial intelligence and machine learning techniques within the Digital Twin further strengthens its predictive capabilities, enabling proactive responses to emerging threats. Experimental results and case studies in industrial automation highlight the effectiveness of the framework in reducing downtime, optimizing resource utilization, and improving overall operational efficiency. This research contributes to the advancement of CPS by establishing a robust methodology for predictive maintenance, demonstrating the potential of Digital Twins as a cornerstone for sustainable and intelligent industrial ecosystems.
Source: Figshare
Author: M, Arul Selvan
Language: English
Subfield: Industrial and Manufacturing Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: green
OpenAlex ID: W7084069135
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