In the world of panel building and mechanical engineering, every day of downtime is one too many. Customers expect new installations to run reliably from day one, without long start-up periods or unexpected failures. At Gerbin Control, we know that this requires an approach that solves problems before they occur.
This is why we are increasingly working with digital twin technology. A digital twin is much more than a 3D model. It is a virtual representation of the control cabinet and the complete control system, enriched with data from sensors, engineering software and simulations. It allows us to see how the panel behaves in practice even before physical delivery.
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What is a digital twin in panel building?
Imagine: you can open, inspect and test a new control panel while it hasn’t even been built yet. That’s essentially what a digital twin makes possible. In Eplan Pro Panel, we set up the complete panel design, including all wiring, components and mounting points. We link this digital version to a data source that is completed at each stage of the project.
Once the first physical components are in place, we add sensor data and PLC logic to the model. From then on, we can simulate how the panel responds to different situations. It’s like having a “digital factory” where we can detect faults, optimize performance and tune processes before even a single cable is connected in the real control cabinet.
The benefits in practice
For us, working with a digital twin is not a theoretical concept, but daily reality. In projects, we notice the impact:
- Shorter commissioning time because configuration issues are already resolved in the simulation phase.
- Higher reliability because errors in cabling, component selection or settings are uncovered early.
- Reduced maintenance costs through predictive analytics based on real-time data.
- More sustainability because energy flows and process settings are optimized in advance.
In a recent assignment for a client in the process industry, we were able to reduce commissioning time by 25 percent. The first three months after commissioning also required fewer interventions, which directly reduced service costs.
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Simulate and test before the panel reaches the shop floor
A major advantage of our approach is that we can simulate the production process in a safe, virtual environment. We build scenarios in which we subject the panel to realistic challenges:
- How does the installation respond to voltage fluctuations?
- What happens if a sensor transmits incorrect values?
- Is the communication between PLC, HMI and field components error-free?
By testing these situations in the digital twin, we know in advance what to expect on site. That gives our commissioning engineers the confidence to work quickly and purposefully during actual commissioning.
The role of remote support and updates
The story doesn’t stop once the panel is up and running. Because the digital twin always remains synchronized with the physical installation, we can monitor, analyze and adjust remotely even after delivery. We first test new software versions in the digital environment. Only when everything works flawlessly do we apply the update to the real installation.
Using AI algorithms and predictive maintenance techniques, we can spot anomalies early. This prevents unnecessary downtime and keeps performance high. The great thing is that all this happens without the need for someone to be physically on site, saving both time and costs.
Contact our experienced innovator
Cees Brasser
With more than 26 years of experience at the helm of Gerbin Control, Cees Brasser is your expert on panel construction for the machinery sector. Discover how his knowledge and insight can take your project to new heights. Get in touch now!
From design to long-term monitoring
At Gerbin Control, the digital twin is not an extra, but an integral part of how we work. We start with a detailed 3D design in Eplan Pro Panel, link it to our PLM system and enrich it with real-time sensor data as soon as the panel goes into operation. This creates one continuous story: from initial design to continuous performance monitoring throughout the life cycle.
Thus, we ensure that customers benefit from a reliable, efficient and future-proof control panel from day one.
Want to know how we use digital twin technology to make your next panel building project faster, safer and more sustainable?Contact our engineers for a customized consultation.
