Andrei-Alexandru CRISTEA1, Silviu RĂILEANU2, Theodor BORANGIU3, Ionuţ Valentin CRISTEA4
Abstract. This article introduces a methodology that leverages the Digital Twin concept to develop, test, and validate advanced control strategies within a virtual environment prior to their onsite implementation. The primary emphasis is on replicating real-time conditions using high-fidelity models and incorporating IoT data streams to accurately reflect actual operations. By integrating digital twins with edge and fog computing architectures, the proposed framework facilitates the remote design of semi-heterarchical control systems, which can be seamlessly incorporated into smart manufacturing settings. The paper examines how this strategy minimizes downtime, expedites deployment, and enhances system reliability while maintaining responsiveness and adaptability in dynamic production environments. The reported research details an architecture based on the open-source event flow programming platform Node-RED. Experimental results are provided for connecting a Digital Twin-based solution for ABB industrial robot programming (RobotStudio) with a unified environment for designing, programming, and managing PLC-based systems from Siemens – the Totally Integrated Automation (TIA) Portal.
Keywords: digital twin, integration, smart manufacturing, industrial robot, PLC.
DOI 10.56082/annalsarsciinfo.2026.1.19
1 Ph.D. student, POLITEHNICA Bucharest, andrei.cristea2107@upb.ro
2 Associate Professor, Ph.D., POLITEHNICA Bucharest, silviu.raileanu@upb.ro
3 University Professor, Ph.D., POLITEHNICA Bucharest, Academy of Romanian Scientists, theodor.borangiu@upb.ro
4 Ph.D. student, POLITEHNICA Bucharest, ionut.cristea1507@stud.acs.upb.ro
PUBLISHED in Annals of the Academy of Romanian Scientists Series on Science and Technology of Information, Volume 19, No1