Development of Digital Twin Modeling for Smart Factory using OpenPLC-Based Control System
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Dec 31, 2025
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Abstract
This research discusses how to design and develop Digital Twin modeling in a Smart Factory system with an OpenPLC-based control system. The main problems in conventional manufacturing systems are limited production line flexibility, difficulty in monitoring and controlling complex devices, and process visualization that is limited to technical data without a real depiction. Through the design of a laboratory-scale mechanical system, the creation of a control board based on an STM32H7 microcontroller with an OpenPLC platform, and the development of a Digital Twin application using Three.js and Node.js, this research produces a Smart Factory prototype that can be visualized in three dimensions and operated in real time via a local network or the internet. Test results show that the system is able to display sensor conditions, control actuators, and accelerate decision-making with shorter response times. The implementation of this system supports production process efficiency and offers an alternative industrial automation solution that is economical, flexible, and more intuitive in the implementation of digital transformation.
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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
How to Cite
Arifianto, M. J., Afianto, & Waluyo Nugroho. (2025). Development of Digital Twin Modeling for Smart Factory using OpenPLC-Based Control System. Jurnal E-Komtek (Elektro-Komputer-Teknik), 9(2), 582-592. https://doi.org/10.37339/e-komtek.v9i2.2856
References
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[6] Fujita, S., Hata, K., Mochizuki, A. et al. OpenPLC based control system testbed for PLC whitelisting system. Artif Life Robotics 26, 149–154 (2021). https://doi.org/10.1007/s10015-020-00635-1
[7] G. Lazaridis, A. Drosou, P. Chatzimisios and D. Tzovaras, "Securing Modbus TCP Communications in I4.0: A Penetration Testing Approach Using OpenPLC and Factory IO," 2023 IEEE Conference on Standards for Communications and Networking (CSCN), Munich, Germany, 2023, pp. 265-270, doi: https://10.1109/CSCN60443.2023.10453119
[8] Hubacz, Marcin, and Bartosz Trybus. 2023. "Dual-Core PLC for Cooperating Projects with Software Implementation" Electronics 12, no. 23: 4730. https://doi.org/10.3390/electronics12234730
[9] Dirksen, Jos. “Learn Three.js : Program 3D Animations and Visualization for the Web with JavaScript and WebGL” , Fourth Edition, 2023, Packt Publishing.
[10] Martinez-Ruedas, Cristina, Jose-Maria Flores-Arias, Isabel M. Moreno-Garcia, Matias Linan-Reyes, and Francisco Jose Bellido-Outeiriño. 2024. "A Cyber–Physical System Based on Digital Twin and 3D SCADA for Real-Time Monitoring of Olive Oil Mills" Technologies 12, no. 5: 60. https://doi.org/10.3390/technologies12050060.
[11] Dirksen, Jos. “Learn Three.js : Program 3D Animations and Visualization for the Web with JavaScript and WebGL” , Fourth Edition, 2023, Packt Publishing.
[12] B. Tomar, N. Kumar, and M. Sreejeth, “Real Time Automation and Ratio Control Using PLC & SCADA in Industry 4.0,” Comput. Syst. Sci. Eng., vol. 45, no. 2, pp. 1495–1516, 2023. https://doi.org/10.32604/csse.2023.030635.
[13] Alexandros Koulouris, Nikiforos Misailidis, Demetri Petrides, Applications of process and digital twin models for production simulation and scheduling in the manufacturing of food ingredients and products, Food and Bioproducts Processing, Volume 126, 2021, Pages 317-333, ISSN 0960-3085, https://doi.org/10.1016/j.fbp.2021.01.016.
[14] Trauer, Jakob, Simon Pfingstl, Markus Finsterer, and Markus Zimmermann. 2021. "Improving Production Efficiency with a Digital Twin Based on Anomaly Detection" Sustainability 13, no. 18: 10155. https://doi.org/10.3390/su131810155
[15] Martinez-Ruedas, Cristina, Jose-Maria Flores-Arias, Isabel M. Moreno-Garcia, Matias Linan-Reyes, and Francisco Jose Bellido-Outeiriño. 2024. "A Cyber–Physical System Based on Digital Twin and 3D SCADA for Real-Time Monitoring of Olive Oil Mills" Technologies 12, no. 5: 60. https://doi.org/10.3390/technologies12050060.
[16] Ndede, Kwaw Tawiah. "A low-cost microcontroller-based PLC for industrial automation of a gold processing plant." (2022).
[17] Niauronis, Saulius. "OPENPLC Hardware Speed Performance Comparison." PROFESSIONAL STUDIES: Theory And Practice 27, no. 1 (2023): 65-71.
[18] H. P. Guntaka, R. Kushalkar, N. Venkat, A. Chipkar, V. Easwaran and K. Moudgalya, "Modular Hardware, Open Source Software and Training Material for PLC Training," 2022 10th International Conference on Control, Mechatronics and Automation (ICCMA), Belval, Luxembourg, 2022, pp. 237-242, doi: https://10.1109/ICCMA56665.2022.10011589.
[19] C. . -. C. Andrei, G. Tudor, M. Arhip-Călin, G. Fierăscu and C. Urcan, "Raspberry Pi, an Alternative Low-Cost PLC," 2020 International Symposium on Fundamentals of Electrical Engineering (ISFEE), Bucharest, Romania, 2020, pp. 1-6, doi: https://10.1109/ISFEE51261.2020.9756175.
[20] Kusuma, E. D., Nugroho, N. A., Suwastono, A., & Sumaryono, S. (2024). Perbandingan Performa OpenPLC dengan PLC Komersial. Journal of Applied Electrical Engineering, 8(2), 125–131.
https://doi.org/10.30871/jaee.v8i2.8710.
[21] M. J. F. Arifianto, dan H. Suprapto, “Perancangan Pengendali Gerakan Stepper Motor menggunakan Mikrokontroller STM32 dengan Tampilan Grafis TouchGFX,” Jurnal Fokus Elektroda., vol. 8, no. 1, pp. 13-20, Feb. 2023, doi: 10.33772/jfe.v8i1.14
[22] Arifianto, Mada Jimmy Fonda, and Lin Prasetyani. "Sistem pemantauan dan kontrol energi listrik menggunakan platform node-red, influxdb dan grafana melalui jaringan wifi dan lora." J. Fokus Elektroda Energi List. Telekomun. Komputer, Elektron. dan Kendali 7, no. 1 (2022): 61. http://dx.doi.org/10.33772/jfe.v7i1.23440.
[2] Florian Biesinger, Davis Meike, Benedikt Kraß, Michael Weyrich, A digital twin for production planning based on cyber-physical systems: A Case Study for a Cyber-Physical System-Based Creation of a Digital Twin, Procedia CIRP, Volume 79, 2019, Pages 355-360, ISSN 2212-8271, https://doi.org/10.1016/j.procir.2019.02.087
[3] Mohsen Soori, Behrooz Arezoo, Roza Dastres, Digital twin for smart manufacturing, A review, Sustainable Manufacturing and Service Economics, Volume 2, 2023, 100017, ISSN 2667-3444, https://doi.org/10.1016/j.smse.2023.100017
[4] M. E. Korkmaz, “A Short Technical Review on Digital Twins in Smart Manufacturing,” Sustainable Production, Instrumentation and Engineering Sciences, vol. 1, no. 1, pp. 1–7, May 2023, doi: https://10.57223/spies.2023.1.1.01.
[5] D. Guerra-Zubiaga, V. Kuts, K. Mahmood, A. Bondar, N. Nasajpour-Esfahani, and T. Otto, “An approach to develop a digital twin for industry 4.0 systems: manufacturing automation case studies,” Int J Comput Integr Manuf, vol. 34, no. 9, pp. 933–949, 2021, doi: https://10.1080/0951192X.2021.1946857.
[6] Fujita, S., Hata, K., Mochizuki, A. et al. OpenPLC based control system testbed for PLC whitelisting system. Artif Life Robotics 26, 149–154 (2021). https://doi.org/10.1007/s10015-020-00635-1
[7] G. Lazaridis, A. Drosou, P. Chatzimisios and D. Tzovaras, "Securing Modbus TCP Communications in I4.0: A Penetration Testing Approach Using OpenPLC and Factory IO," 2023 IEEE Conference on Standards for Communications and Networking (CSCN), Munich, Germany, 2023, pp. 265-270, doi: https://10.1109/CSCN60443.2023.10453119
[8] Hubacz, Marcin, and Bartosz Trybus. 2023. "Dual-Core PLC for Cooperating Projects with Software Implementation" Electronics 12, no. 23: 4730. https://doi.org/10.3390/electronics12234730
[9] Dirksen, Jos. “Learn Three.js : Program 3D Animations and Visualization for the Web with JavaScript and WebGL” , Fourth Edition, 2023, Packt Publishing.
[10] Martinez-Ruedas, Cristina, Jose-Maria Flores-Arias, Isabel M. Moreno-Garcia, Matias Linan-Reyes, and Francisco Jose Bellido-Outeiriño. 2024. "A Cyber–Physical System Based on Digital Twin and 3D SCADA for Real-Time Monitoring of Olive Oil Mills" Technologies 12, no. 5: 60. https://doi.org/10.3390/technologies12050060.
[11] Dirksen, Jos. “Learn Three.js : Program 3D Animations and Visualization for the Web with JavaScript and WebGL” , Fourth Edition, 2023, Packt Publishing.
[12] B. Tomar, N. Kumar, and M. Sreejeth, “Real Time Automation and Ratio Control Using PLC & SCADA in Industry 4.0,” Comput. Syst. Sci. Eng., vol. 45, no. 2, pp. 1495–1516, 2023. https://doi.org/10.32604/csse.2023.030635.
[13] Alexandros Koulouris, Nikiforos Misailidis, Demetri Petrides, Applications of process and digital twin models for production simulation and scheduling in the manufacturing of food ingredients and products, Food and Bioproducts Processing, Volume 126, 2021, Pages 317-333, ISSN 0960-3085, https://doi.org/10.1016/j.fbp.2021.01.016.
[14] Trauer, Jakob, Simon Pfingstl, Markus Finsterer, and Markus Zimmermann. 2021. "Improving Production Efficiency with a Digital Twin Based on Anomaly Detection" Sustainability 13, no. 18: 10155. https://doi.org/10.3390/su131810155
[15] Martinez-Ruedas, Cristina, Jose-Maria Flores-Arias, Isabel M. Moreno-Garcia, Matias Linan-Reyes, and Francisco Jose Bellido-Outeiriño. 2024. "A Cyber–Physical System Based on Digital Twin and 3D SCADA for Real-Time Monitoring of Olive Oil Mills" Technologies 12, no. 5: 60. https://doi.org/10.3390/technologies12050060.
[16] Ndede, Kwaw Tawiah. "A low-cost microcontroller-based PLC for industrial automation of a gold processing plant." (2022).
[17] Niauronis, Saulius. "OPENPLC Hardware Speed Performance Comparison." PROFESSIONAL STUDIES: Theory And Practice 27, no. 1 (2023): 65-71.
[18] H. P. Guntaka, R. Kushalkar, N. Venkat, A. Chipkar, V. Easwaran and K. Moudgalya, "Modular Hardware, Open Source Software and Training Material for PLC Training," 2022 10th International Conference on Control, Mechatronics and Automation (ICCMA), Belval, Luxembourg, 2022, pp. 237-242, doi: https://10.1109/ICCMA56665.2022.10011589.
[19] C. . -. C. Andrei, G. Tudor, M. Arhip-Călin, G. Fierăscu and C. Urcan, "Raspberry Pi, an Alternative Low-Cost PLC," 2020 International Symposium on Fundamentals of Electrical Engineering (ISFEE), Bucharest, Romania, 2020, pp. 1-6, doi: https://10.1109/ISFEE51261.2020.9756175.
[20] Kusuma, E. D., Nugroho, N. A., Suwastono, A., & Sumaryono, S. (2024). Perbandingan Performa OpenPLC dengan PLC Komersial. Journal of Applied Electrical Engineering, 8(2), 125–131.
https://doi.org/10.30871/jaee.v8i2.8710.
[21] M. J. F. Arifianto, dan H. Suprapto, “Perancangan Pengendali Gerakan Stepper Motor menggunakan Mikrokontroller STM32 dengan Tampilan Grafis TouchGFX,” Jurnal Fokus Elektroda., vol. 8, no. 1, pp. 13-20, Feb. 2023, doi: 10.33772/jfe.v8i1.14
[22] Arifianto, Mada Jimmy Fonda, and Lin Prasetyani. "Sistem pemantauan dan kontrol energi listrik menggunakan platform node-red, influxdb dan grafana melalui jaringan wifi dan lora." J. Fokus Elektroda Energi List. Telekomun. Komputer, Elektron. dan Kendali 7, no. 1 (2022): 61. http://dx.doi.org/10.33772/jfe.v7i1.23440.