ACADEMIA Letters

Use of Digital Twin in Electropneumatic Systems

Lucas Pinto

Evolution in current industrial processes will not be possible without a series of technological
advances, including the successful realization of the digital twin and the threads that connect it
to the physical world. Digital transformation has been happening over the years in most com-
panies. The way we track data or transactions and the way we collaborate and communicate
has changed and undergo significant advances through digital technology. That’s why there
is a need for new types of technologies for this wave of digitization – a technology that com-
bines digital objects with physical objects in a dynamic, learning and interactive way. Digital
twins provide a way to model and manage the complexities inherent in products. Virtually
modeling a product helps companies avoid costly quality issues or manufacturing rework, as
manufacturing and performance variables can be modeled before they occur. Digital twins
can therefore help manufacturers make their products or automate their processes for the first
time without fail, and help development and support teams share the same product knowledge
regardless of location. Creating a digital twin of a production system opens up new ways to
improve productivity on some production machines and even entire facilities. Extending this
concept from product to production also contributes to the idea of improving the operation
of continuous processes and not just product manufacturing through them. The purpose of
connecting the simulation systems was to communicate with physical systems, using an easy-
port USB. It is necessary to carry out the simulation of an electropneumatic system by the
FluidSIM software, with precise adaptations so that the process simulation is communicated
with a Programmable Logic Controller (PLC). For this experiment, FluidSIM Pneumática,
Festo FST, EzOPC, a 24V voltage source, an EasyPort USB, a digital I/O crossover signal
cable 167106, CLP FEC FC34 were used. A sequential electropneumatic system with two
piston cylinders was created. The algebraic sequence used was 1A+ 2A+ 2A-1A-. The sys-
tem starts up by means of a two-hand command with normal open (NO) actuation buttons.

Academia Letters, June 2021 ©2021 by the author — Open Access — Distributed under CC BY 4.0

Corresponding Author: Lucas Pinto, lucas.engmect@gmail.com

Citation: Pinto, L. (2021). Use of Digital Twin in Electropneumatic Systems. Academia Letters, Article 1202.
https://doi.org/10.20935/AL1202.

1
The first step to use is to perform the simulation. For the initial test, a simple system with
two sequential cylinders was used. The operation initially takes place by activating the two
buttons simultaneously where cylinder 1A advances, at the end of the stroke cylinder 2A ad-
vances and returns when the stroke ends, and only at the end of this cycle does cylinder 1A
retreat. We have to pay attention to the connections in the input and output components of
FluidSIM. The output port (FluidSIM Out) will receive the connections of the input signals
and, in the same way, the input port (FluidSIM In) will be connected to the output signals.
Once the simulation scheme is done, we have to configure FluidSIM to carry out external
communication. The following steps are essential for correct operation. On the menu bar,
select Options> Connection OPC / DDE…It is necessary to configure the input and output
ports of FluidSIM. Clicking on each of them will open a screen like below. Click search to
select the correct version that is available. It is necessary to know which version and server is
available, in this case the EzOPC.1 server in version 4 was used. The step must be performed
on both ports. Ladder programming was developed for PLC’s and is based on simple switches
that are connected in lines with coils in order to compose logic circuits. Thus, each switch
(input) receives an identification as well as the coils (outputs). Start creating a new project.
From the menu bar select Project > New…Then you are asked to name the project. Aftar
that, start creating a new schedule. New > Ladder Diagram. You will be asked for a program
number, chosen by whoever is programming. When placing the input and output signals, it
must be placed in some port that will be important when making the physical connections.
When naming the input/output, you will be asked to allocate it. To check the allocations, from
the left menu select “Allocation List”. Checks must be done before sending to PLC. For that,
it is necessary to follow the steps: Compile > Make > Build. If there are no errors, download
it to the PLC. The EzOPC software was developed to allow control of simulated circuits in
FluidSIM through an external PLC. In addition to digital signals, analog values can be shared
and these signals can also be connected to a real process or PLC via EasyPort-Modules. After
recognition, on the Overview tab, for this simulation and to make the virtual control, it is nec-
essary to select the “Process via EasyPort” and “Controller in FluidSIM. Now it’s just a matter
of making all the physical connections and putting all the systems “online”. When connecting
EasyPort to computer by USB cable and PLC by digital crossover I/O signal cable 167106,
it is necessary to recognize by OPC. In the EasyPort tab, look for the module connected in
“Search EasyPorts”. Digital transformation is directly linked to technology. Digital twins are
a virtualized copy of real processes, meaning that while a new product is developed on the
physical plane, its creation is digitally emulated in all its aspects. For this, sensors are used
that capture information from the environment and apply this data in the simulation of digital
twins, and then they are analyzed and tested virtually before being transferred to the actual

Academia Letters, June 2021 ©2021 by the author — Open Access — Distributed under CC BY 4.0

Corresponding Author: Lucas Pinto, lucas.engmect@gmail.com

Citation: Pinto, L. (2021). Use of Digital Twin in Electropneumatic Systems. Academia Letters, Article 1202.
https://doi.org/10.20935/AL1202.

2
product. Developing a new product involves a number of challenges. In addition to investment
costs, it is necessary to have agility in development without losing effectiveness, facing as few
setbacks as possible. The advantages of applying this technology include reducing production
time and costs, expanding adaptability, improving earnings predictability, and improving risk
prediction and error correction. With the system already implemented, the collected data can
be tested and analyzed immediately, shortening the learning curve for product development
in virtual tools, reducing the overall cost of the manufacturing process, with the tests being
strongly supported by the realities of the company and the market . By digitizing the product
development, it is possible to know whether the investments made will be profitable or not and
under what conditions, in addition to managing risks and detecting errors quickly and reliably.
To exploit the digital twin in electropneumatic systems, it is necessary, first of all, to gather
the right equipment. It is also worth mentioning that, in the same way that we use a simple
and small circuit and, based on the result obtained in a satisfactory manner, the technology
can be implemented in any system with greater complexity that guarantees its operation.

Academia Letters, June 2021 ©2021 by the author — Open Access — Distributed under CC BY 4.0

Corresponding Author: Lucas Pinto, lucas.engmect@gmail.com

Citation: Pinto, L. (2021). Use of Digital Twin in Electropneumatic Systems. Academia Letters, Article 1202.
https://doi.org/10.20935/AL1202.