Arvantti Labs is the intelligence solutions brand of Sequoia Space. Today I am going to show you, without technicalities, what Arvantti-DigitalTwin® is, our digital twin that co-simulates your plant, how it works with Arvantti-Fractal®, our predictive event analyzer, both registered trademarks, and how it can help you see and anticipate what is happening in your plant.

Let's start with the challenge. In most plants, decisions are reactive: we find out about the problem when it has already happened. Testing a change directly in the actual plant is risky and expensive, because it can lead to waste or downtime. And although the PLC records many signals, it is difficult to see the big picture and anticipate what is coming. The question we want to answer is: what if you could rehearse tomorrow before living it, without touching the operation?

A digital twin is, in simple words, a living copy of your plant. It is not a plan or an animation: it is a virtual replica that moves at the rhythm of the real plant, with the same equipment and the same signals. It helps you do three things: see the complete plant in 3D with its live state, understand what happens in each piece of equipment, and rehearse changes and scenarios without touching the operation. The image is one of our reference plants, a sauces and dressings plant; Your data are demo estimates, not from an actual installation.

This is how an Arvantti digital twin operates. On the left, the real plant with its equipment and sensors or, if the plant is still a project, Arvantti-Emulator®, which emulates it with a calculation algorithm. Reality does not talk directly to the twin: it goes through the control layer. That can be the real PLC, a virtual PLC inside the emulator, or a production management program, such as Excel tables or software with the sequences and routings. That data reaches Arvantti-DigitalTwin®, our digital twin and registered trademark, via OPC UA, and it shows the plant in 3D in real time: the past and the present. Arvantti-Fractal®, also a registered trademark, gives the twin a view of the future: it builds scenarios, optimizes, anticipates events and recommends the best adjustment, which is shown on the same twin. That result feeds Advanced Planning & Scheduling, APS, which feeds the optimal plan back to the digital twin and to the ERP or production management program. The operator decides whether to accept it, and only then is the adjustment applied in the PLC; Fractal never writes directly to the PLC. In the demonstration plants the PLC is virtualized; the same setup connects to a real PLC in read-only mode.

The digital twin is at the center of a hexagonal system of sources: PLC, ERP and MES, Advanced Planning and Scheduling (APS), cameras and vision, IoT sensors and Arvantti-Emulator®. No connection to the PLC required: it works with at least one of these sources. With PLC or SCADA you see the plant live; with sensors, ERP or cameras it works without touching the plant control; and if the plant is still a project, Arvantti-Emulator®, a registered trademark, simulates it with a virtual PLC. Arvantti-DigitalTwin® is also a registered trademark.

The twin is built in three phases. First we connect: we read the PLC signals in read-only mode and assemble the plant in 3D with our equipment library; The result is that you see your plant live. If the plant is still a project, we build the emulator with virtual PLC simulation using Arvantti-Emulator®, registered trademark. Second, we co-simulate: Arvantti-DigitalTwin®, a registered trademark, runs its own model of the plant in parallel, independent of the operation, to project what may happen in the next few hours. Third, we optimize: Arvantti-Fractal®, registered trademark, compares alternatives, anticipates events and recommends adjustments, but the decision is always your team's.

Arvantti-DigitalTwin® and Arvantti-Fractal® are registered trademarks of Arvantti Labs. Arvantti-DigitalTwin® co-simulates the plant and Arvantti-Fractal® analyzes the predictive events and recommends. First, it reads signals from the PLC in read-only mode: it never writes to the PLC or the plant. Second, it runs its own model, independent of the one that represents the operation. Third, project 24-hour scenarios: the current plan, which we call the base case, against alternatives. Fourth, anticipate events before they occur. And fifth, recommends: the recommendation reaches the operator, who accepts or rejects it. In the demonstration scale aqueduct, alternative studies are shown marked as not applied until the operator decides. Keep in mind that this plant is a demonstration plant and its PLC is virtualized.

We do not build each twin from scratch. We use a library of standardized equipment: each equipment is a parametric 3D model, which adjusts to the size and configuration of yours, plus simulated behavior with cycles, flows, faults and alarms in the correct order of magnitude. If your plant has equipment that is not yet in the library, we create it from photos, catalogs or data plates: we do a short interview, you confirm a file and the equipment enters the library. Each team honestly states which data is real and which is assumptions. The image is the plastic injection reference plant, with demonstration data.

These are some examples, with real views of the platform: four reference floors built with the Arvantti equipment library. A plastic injection plant, as an example of discrete manufacturing; a sauces and dressings plant, manufacturing by processes, with batch and continuous stages; a scale aqueduct, as an example of a water network; and airport baggage handling, as a logistical example. The data from these plants are plausible demonstration estimates, not from an actual installation. Each plant has a link to open it in 3D at digitaltwin.arvantti.online.

We virtualize your plant controls: a control room that shows on a single screen the status of each piece of equipment and line, live key variables, prioritized alarms and events, and trends over the last 24 hours. The panel on this slide is an illustrative example with sample values; In each project it is assembled with the equipment and signals of your plant. If the plant is still a project, Arvantti-Emulator® simulates the controls with a virtual PLC.

The digital twin applies to any operation with equipment and signals. In discrete manufacturing, such as molding, packaging and assembly lines; Our reference is a plastic injection plant. In process manufacturing, with batch and continuous production, such as food; The reference is a sauces and dressings plant. In logistics and airports, with belts, classification and material flow; The reference is airport baggage handling. And in public services and cities: water networks, with the aqueduct to scale, and an urban traffic twin that is under development. All are reference plants with demonstration data.

A key point for any plant manager: you remain in control. The AI ​​recommends, but no setting is applied without a person accepting it. Arvantti-Fractal® reads the PLC in read-only mode and never writes directly to it or the plant. Each recommendation, decision and change is recorded, so that there is traceability. And everything that is simulated, or an alternative that is not yet applied, is marked as such, so that it is never confused with reality. All of this is governed by Arvantti Harness®, a registered trademark, which is the basis of permissions and control of the Arvantti ecosystem.

This is how we start. First, a diagnosis: we understand your process, your data and what decision you want to anticipate. Second, the plant model: we assemble your plant in 3D with the equipment library and create the missing ones from photos or catalogs. Third, the connection to your sources: PLC, SCADA, sensors, ERP or cameras; All you need is one, always in read-only mode, and we validate the data against the operation. If the plant is still a project, we use Arvantti-Emulator®. Fourth, the start-up: Arvantti-DigitalTwin® co-simulates a specific process and we measure the results. The recommendation is to start with a specific process and grow from the results. The times and scope are defined in the diagnosis.

We close with an open question: what part of your plant do you want to see before it happens? Based on your response, we propose the scope of the digital twin and the pilot with Arvantti-Fractal®. My contact information is on the screen: Andrés Quiceno, CTO of Engineering, [email protected], and the Arvantti and Sequoia Space LinkedIn sites and pages.