Digital Twin Technologies in Predictive Maintenance: Enabling Transferability via Sim-to-Real and Real-to-Sim Transfer

The advancement of the Internet of Things (IoT) and Artificial Intelligence has catalyzed the evolution of Digital Twins (DTs) from conceptual ideas to more implementable realities. Yet, transitioning from academia to industry is complex due to the absence of standardized frameworks. This paper builds upon the authors' previously established functional and informational requirements supporting standardized DT development, focusing on a crucial aspect: transferability. While existing DT research primarily centers on asset transfer, the significance of "sim-to-real transfer" and "real-to-sim transfer"--transferring knowledge between simulations and real-world operations--is vital for comprehensive lifecycle management in DTs. A key challenge in this process is calibrating the "reality gap," the discrepancy between simulated predictions and actual outcomes. Our research investigates the impact of integrating a single Reality Gap Analysis (RGA) module into an existing DT framework to effectively manage both sim-to-real and real-to-sim transfers. This integration is facilitated by data pipelines that connect the RGA module with the existing components of the DT framework, including the historical repository and the simulation model. A case study on a pedestrian bridge at Carnegie Mellon University showcases the performance of different levels of integration of our approach with an existing framework. With full implementation of an RGA module and a complete data pipeline, our approach is capable of bidirectional knowledge transfer between simulations and real-world operations without compromising efficiency.