Digital Twin Platform

NexaTwin a digital twin for validation, LiveTwin & 3D HMI

NexaTwin is a modular digital twin for machinery and equipment. It supports virtual commissioning by validating mechanics and software, maps processes as a LiveTwin with real-time data, and integrates the HMI directly into one solution. Four modules and two add-on modules enable flexible adaptation to different machines, processes, and applications.

Layout Manager

NexaTwin – Layout Manager

With Layout Manager, you can visualize your machine and plant layout early on in the digital twin. Geometry, material flow, and the positioning of sensors and actuators thus become quickly comprehensible. Detailed adjustments can be implemented efficiently directly on the model and secured early in the project phase.

The UI functions in the digital twin allow users to select system components and automatically navigate to them directly within the model via a camera path.

In the digital twin, sensors and actuators can also be selected and controlled directly in the model via automatic camera guidance.

The show/hide function allows specific plant components in the digital twin to be made visible or invisible.

Sensors and actuators can be individually shown and hidden in the digital twin to focus on relevant components.

Layout Manager – Your Benefits

Understand machine layout early on
The digital twin makes the machine and plant layout visible early on and enables a clear presentation beyond classic drawings.
Easy navigation and simulation
The intuitive operation facilitates access to the model and supports motion simulation in the digital twin.
Implement Adjustments Efficiently
Changes and detailed adjustments can be discussed quickly and cost-effectively directly on the model.
Faster component identification
System components can be specifically located, which better prepares the installation of sensors, light barriers, motors, and cylinders.
Better Basis for Software Work
The Layout Manager supports programmers and service providers with a visual basis for more efficient software preparation.

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Mechanical Validation

NexaTwin – Mechanical Validation

With Mechanic Validation, you check kinematics, range of motion, and potential collisions early in the digital twin. This way, you reduce risks and avoid costly crashes before the system is on the construction site.

In Unity mode, actuators and sensors in the digital twin can be specifically moved and observed without a connected control system.

In case of a mechanical malfunction, affected actuators are automatically highlighted in red in the digital twin.

The Collision Tracer makes component collisions in the digital twin permanently visible as volume stamps.

The Volume Tracer records defined 3D geometries as a volume cloud and makes movement spaces precisely traceable.

The Point Tracer makes defined work points in the digital twin precisely traceable for motion sequences and target positions.

Mechanic Validation – Your Benefit

Early kinematics checks
Motion sequences, axes, and travel paths can be realistically evaluated in the digital twin even before the system is physically built.
Early collision detection
Potential collisions between components and plant areas become visible early, so that expensive damage and mechanical conflicts are avoided in good time.
Safely Validate Movement Spaces
Movement spaces of defined components can be precisely tracked and checked for freedom of movement, end positions, and critical areas.
Reducing risks on the construction site
Mechanical problems are already identified during virtual commissioning, which significantly reduces rework, downtime, and unplanned on-site deployments.
Targeted Preparation for Commissioning
Mechanic Validation creates a reliable foundation for design, programming, and fine-tuning, and accelerates the preparation of the real system.

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Software Validation

NexaTwin – Software Validation

Software validation makes it possible to test control logic, process flows, and error cases early on in the digital twin. This creates reproducible tests, reduces coordination loops on-site, and accelerates the commissioning of the real plant.

In the digital twin, system functions controlled via the control system can be specifically tested and optimized even before actual commissioning.

Malfunctions are detected early in the digital twin, reliably analyzed, and rectified before commissioning.

Component tracking with complex tracking logic can also be reliably tested in the digital twin together with the PLC.

Software Validation - Your Benefits

Significantly shorter commissioning times
Control logic, processes, and error cases are already tested in the digital twin, which reduces on-site iterations and speeds up real-world commissioning.
Identify and correct errors earlier
Problems in PLC logic and plant sequences can be identified and specifically corrected even before deployment on site.
Reproducible Test Execution
Functions, sequences, and error cases can be systematically tested during virtual commissioning and repeated at any time under identical conditions.
Efficiently coordinate software together
Programming, mechanical engineering, and the end customer can jointly test processes and functions directly on the digital twin and release them significantly faster.

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Live Twin

NexaTwin – Live Twin

With LiveTwin, the digital twin becomes a real-time view of your plant. States, signals, and correlations become visually traceable, allowing disturbances to be analyzed faster, restarts to be carried out more precisely, and downtimes to be reduced.

The LiveTwin displays the current plant status in real‑time and makes malfunctions and status changes immediately visible in the model.

Live Twin - Its Uses

Real-time plant status acquisition
LiveTwin maps the current state of the plant directly to the digital twin, making signals, status changes, and correlations visually comprehensible.
Faster fault analysis
Error causes can be identified more quickly in LiveTwin because affected areas, states, and processes become immediately visible in the model.
Targeted support for restarts
In the event of malfunctions and recommissioning, the digital twin helps to assess system statuses more quickly and to prepare the restart more safely and efficiently.
Sustainably reduce downtimes
The transparent real-time display of the system significantly accelerates diagnosis, communication, and reaction in the event of service.
Better knowledge retention in teams
LiveTwin makes operating conditions and plant behavior vividly visible, shortens training times, and reduces dependency on individual key personnel.

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HMI

NexaTwin – HMI

The HMI in NexaTwin combines operation and visualization in one interface. This allows functions to be controlled and states to be viewed directly on the model. This significantly increases comprehensibility during operation compared to classic 2D masks.

The NexaTwin HMI has all the necessary functionalities of classic machine control panels. In addition to various manual functions, it also includes an alarm system, user management, and recipe management.

HMI - Your Benefit

Experience seamless software integration
Benefit from a fully integrated solution that is ready for use directly from software validation and via LiveTwin. No complicated interfaces, but a continuous workflow.
Enhance Plant Control with Interactive 3D Visualization
Say goodbye to static views. Modern 3D visualization of your plant not only makes operation more visually appealing but also significantly more practical and intuitive.
Intuitive User Guidance Instead of Complex 2D Systems
Opt for maximum clarity. NexaTwin offers clearer user guidance than classic 2D systems, which shortens the training period and increases operational reliability.
Achieve up to 75% cost savings with full performance
Rethinking cost-effectiveness: Get a high-performance HMI solution that is significantly more cost-effective compared to established manufacturers, without compromising on quality.