Accelerate your journey towards an AI Digital Twin

Sam Verdonck
January 30, 2024
December 22, 2023
min read

In the ever-evolving landscape of industrial machinery, staying competitive and efficient is crucial. Fortunately, the advent of AI digital twins has opened up a realm of possibilities for industries seeking to optimize their operations, improve reliability, and reduce downtime.

These digital twins, driven by Machine Learning (ML), offer a numerical representation of assets or processes that can transform the way we design, engineer, produce, and service these crucial elements of our industrial world.

In this article, I'll delve into the potential of AI digital twins for industrial machinery and explore the role of time series machine learning and normal behavior modeling in making this groundbreaking technology work.

Accelerate your journey towards an AI Digital Twin

Understanding AI Digital Twins

An AI digital twin is essentially a digital replica of a physical asset or process, leveraging ML algorithms to simulate and monitor its behavior. The goal is to create a virtual entity that mirrors the real-world counterpart so closely that it can offer insights and predictions that lead to more efficient operations and maintenance.  

There are various ways to approach this, but one way to look at it is to use the time-series data from the machine and process to build a normal behavior model as the initial AI digital twin of your machine.

Here's a step-by-step approach to achieving this type of AI digital twin of an asset with a technology like Tangent by Tangent Works:

1. Drift Monitoring on Individual Sensors

The journey towards creating an AI digital twin begins with the monitoring of individual sensors. Sensors attached to machinery collect vast amounts of data, including temperature, pressure, vibration, and more. By continuously monitoring these sensors, it's possible to detect subtle changes in the asset's behavior, which can be indicative of potential issues.

2. System-Driven Anomaly Detection

While monitoring individual sensors is essential, it's equally important to consider the overall system behavior. System-driven anomaly detection focuses on understanding whether the data from IoT sensors collectively behave normally. If there are inconsistencies or patterns that deviate from the norm, this can signify potential problems that require attention.

3. KPI-Driven Anomaly Detection

KPI-driven anomaly detection looks at critical metrics, such as generated power in the case of a power plant, to detect performance problems early. By closely monitoring KPIs, industries can proactively address issues before they lead to costly downtime.

4. Forecast Asset Performance for Optimization

One of the significant advantages of AI digital twins is their ability to forecast asset performance. By utilizing time series machine learning, industries can generate accurate predictions about future behavior. For instance, in the energy sector, day-ahead power forecasts can help operators optimize their operations and plan for any potential disruptions.

5. Forecast Remaining Useful Lifetime and Predictive Maintenance

Perhaps one of the most promising applications of AI digital twins is predictive maintenance. By forecasting the remaining useful lifetime of an asset, industries can plan maintenance activities more efficiently. This leads to fewer on-site inspections, reduced downtime, and cost savings.

As we progress through these steps, the complexity of the AI digital twin increases. This is where technologies like Tangent come into play. They help streamline the process, remove complexity, and enable industries to quickly operationalize basic AI digital twins and progress through this journey towards advanced predictive analytics. Tangent accelerates the journey towards data-driven operations, allowing businesses to gain a serious competitive advantage.

Accelerate your journey towards an AI Digital Twin

The Potential of AI Digital Twins

The potential of AI digital twins is staggering. These virtual replicas offer a wealth of benefits across various industries, including manufacturing, energy, healthcare, and more. Let's explore some of the key advantages:

1. Improved Efficiency

AI digital twins enable real-time monitoring and optimization, leading to improved efficiency in operations. This efficiency translates into cost savings and increased productivity.

2. Enhanced Reliability

By proactively identifying anomalies and predicting maintenance needs, AI digital twins enhance the reliability and uptime of industrial machinery, reducing costly downtime.

3. Cost Savings

Predictive maintenance and optimized operations result in substantial cost savings. Industries can reduce unnecessary inspections and minimize the risk of catastrophic failures.

4. Data-Driven Decision-Making

AI digital twins empower businesses with data-driven decision-making capabilities. They provide actionable insights that help organizations make informed choices about asset management and operations.

5. Competitive Advantage

Industries that leverage AI digital twins gain a competitive edge. They can deliver higher-quality products and services while maintaining a competitive cost structure.


AI digital twins represent a transformative technology that holds the potential to revolutionize the industrial machinery landscape. By following a step-by-step approach that leverages time series machine learning and normal behavior modeling, businesses can start to unlock the full potential of AI digital twins Today. These digital replicas offer unparalleled insights, efficiency gains, and cost savings, making them a game-changer for industries looking to thrive in the digital age.

With tools like Tangent by Tangent Works, the journey towards data-driven operations becomes more accessible, ensuring that AI digital twins are within reach for industries of all sizes. It's an exciting time for industrial innovation, and AI digital twins are at the forefront of this revolution.

Article by Sam Verdonck, Chief Growth Officer at Tangent Works

Connect with Sam on LinkedIn!  

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