Methodology to develop Digital Twins for energy efficient customizable IoT-Products
Open accessAbstract
Products are increasingly individualized and enhanced to be able to communicate, e.g. via Industrial Internet of Things (IoT). However, the impact of products on sustainability (environmental and social) across their life is often not considered and analyzed. IoT-based or smart products, that are able to communicate, generate data, which can be used to monitor and optimize sustainability indicators. The Digital Twin (DT) is a new technological concept which focuses on product individual data collection and analysis. It provides the possibility to make use of the available data and optimize the systems individual sustainability as well as future product generations. However, the design and realization of such a DT requires new approaches and capabilities, which is an identified research gap. Therefore, this paper presents a methodology to develop DTs of physical IoT-based products, the so called DT V-Model with the aim to optimize the systems sustainability, specifically environmental aspects. It is based on the V-model for the development of smart products and is enhanced with additional roles and approaches for DT development. The methodology is described in detail. The result of a development cycle according to the DT-V-Model is a tested concept of a DT, which includes Digital Master (DM) data from the planning phase and Digital Shadow (DS) data from the production, operation and End of Life-phase. For a DT for energy efficiency, the Digital Master model consists of the information and models from the product development phase including the planned production and use phase energy consumption. The Digital Shadow consists of the actual production energy consumption and the use phase energy consumption. The methodology is applied to a use case of an IoT-based consumer product that can be customized to a certain degree by the consumer. A DT is developed to monitor and optimize the products energy efficiency in production and use. The necessary elements of the DT and the capabilities are depicted. The paper shows the feasibility of the methodology for the development of DTs, the necessary adaptions to common approaches for development and the specific characteristics of DT development for the aim of energy efficiency.
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Riedelsheimer et al. observed reductions in operating costs in renewable energy systems, where real-time monitoring and predictive adjustments of wind turbine and solar panel performance led to greater efficiency.
“Similarly, Riedelsheimer et al. [32] observed reductions in operating costs in renewable energy systems, where real-time monitoring and predictive adjustments of wind turbine and solar panel performance led to greater efficiency.”
From Analysis of Digital Twin Applications in Energy Efficiency: A Systematic Review (2025) · cites this paper as [32]
Section 4 (page not provided) describes a smart-coaster digital twin developed to monitor energy use and recommend efficiency optimizations. It does not report reduced operating costs or study renewable-energy systems, wind turbines, or solar panels; its recommendations are not reported as predictive adjustments to those systems. (LLM, conf=0.88)
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Cites
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Cited by
Sorted by citations
Analysis of Digital Twin Applications in Energy Efficiency: A Systematic Review
Ba, L., Tangour, F., El Abbassi, I., & Absi, R. (2025) · Sustainability · doi:10.3390/su17083560 · Cited by 96 · see citing works
Sustainable product lifecycle management with Digital Twins: A systematic literature review
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Self-citation
- Authors
- Riedelsheimer, T., Gogineni, S., & Stark, R.
- Affiliations
- Fraunhofer Institute for Production Systems and Design Technology (DE)
- Technische Universität Berlin (DE)
- Corresponding author
- Riedelsheimer, Theresa
- ORCID
- Stark, Rainer
- Venue
- Procedia CIRP
- Publisher
- Elsevier BV
- Published
- 2021
- Volume
- 98
- Pages
- 258-263
- ISSN
- 2212-8271 (ISSN-L)
- OpenAlex
- W3136739333
- Cited by
- 49
- References
- 3
- Citations by year
- 2026: 4 · 2025: 9 · 2024: 11 · 2023: 14 · 2022: 8 · 2021: 3
- FWCI
- 4.65
- Type
- journal article
- Language
- en
- Open access
- diamond
- doi.org
- Licence
- Locations
- Procedia CIRP (publishedVersion, cc-by-nc-nd)
- Publikationsdatenbank der Fraunhofer-Gesellschaft (Fraunhofer-Gesellschaft) (submittedVersion, other-oa)
- Fraunhofer-Publica (Fraunhofer-Gesellschaft) (submittedVersion)
- Funders
- European Regional Development Fund
- Topics
- Physical Sciences › Engineering › Industrial and Manufacturing Engineering › Digital Transformation in Industry
- Physical Sciences › Engineering › Industrial and Manufacturing Engineering › Applied Advanced Technologies
- Social Sciences › Business, Management and Accounting › Management of Technology and Innovation › Product Development and Customization
- Keywords
- digital twin, Industrial Internet of Things, energy efficiency, V-model, customizable products, energy consumption monitoring, end of life, product development methodology
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