Optimizing Digital Twin Synchronization in a Finite Horizon

Given the tendency to increase the complexity of digital twins to capture a manufacturing system in the most detailed way, synchronizing and using a complex digital twin with the real-time data may require significant resources. We define the optimal synchronization problem to operate the digital twins in the most effective way by balancing the trade-off between improving the accuracy of the simulation prediction and using more resources. We formulate and solve the optimal synchronization problem for a special case. We analyze the characteristics of the state-dependent and state-independent optimal policies that indicate when to synchronize the simulation at each decision epoch. Our numerical experiments show that the number of synchronizations decreases with the synchronization cost and with the system variability. Furthermore, a lower average number of synchronizations can be achieved by using a state-dependent policy.