Virtualized Digital Twin (DT) of a Reconfigurable Programmable Logic Controller (PLC)

This paper explores the intersection of digital twin technology and Programmable Logic Controllers (PLCs) within the scope of industrial automation, emphasizing the transformative potential of these technologies in enhancing the efficiency and functionality of PLCs. By leveraging the capabilities of OpenPLC—an open-source software—this research aims to demonstrate the significant advancements in automation practices that can be achieved by simulating PLC systems virtually. This approach not only promises more reliable and cost-effective automation solutions but also significantly improves design and operational effectiveness, thus marking a significant leap forward in the automation domain. Central to our study is the integration of digital twin technology, which facilitates the real-time simulation, analysis, and optimization of automated systems, thereby reducing costs and commissioning times. The paper also highlights the adoption of fully open-source software to address the scalability of inputs and outputs in automation systems, overcoming the limitations imposed by physical hardware. Our methodology utilizes the OpenPLC runtime deployed within a Docker container to ensure scalable and efficient system deployment. Furthermore, the system setup incorporates MQTT for efficient data transmission and a custom Python script to facilitate communication between virtual and physical PLCs through MQTT and MODBUS protocols. Uniquely, this research offers a groundbreaking perspective by combining the robustness of open-source tools with the precision of digital twins, paving the way for future innovations in automated control systems and setting a new benchmark for open, scalable, and highly efficient industrial automation frameworks.