The Digital Twin is a well-known concept of Industry 4.0 and is the cyber part of a cyber-physical production system providing several benefits such as virtual commissioning or predictive maintenance. The existing production systems are lacking a Digital Twin which has to be created manually in a time-consuming and error-prone process. Therefore, methods to create digital models of existing production systems and their relations between them were developed. This paper presents the implementation of the methodology for the creation of multi-disciplinary relations and a quantitative and qualitative evaluation of the benefits of the methodology.

The creation of a Digital Twin for existing manufacturing systems, so-called brownfield systems, is a challenging task due to the needed expert knowledge about the structure of brownfield systems and the effort to realize the digital models. Several approaches and methods have already been proposed that at least partially digitalize the information about a brownfield manufacturing system. A Digital Twin requires linked information from multiple sources. This paper presents a graph-based approach to merge information from heterogeneous sources. Furthermore, the approach provides a way to automatically identify templates using graph structure analysis to facilitate further work with the resulting Digital Twin and its further enhancement.

The success of the reconfiguration of existing manufacturing systems, so called brownfield systems, heavily relies on the knowledge about the system. Reconfiguration can be planned, supported and simplified with the Digital Twin of the system providing this knowledge. However, digital models as the basis of a Digital Twin are usually missing for these plants. This article presents a data-driven approach to gain knowledge about a brownfield system to create the digital models of a Digital Twin and their relations. Finally, a proof of concept shows that process data and position data as data sources deliver the relations between the models of the Digital Twin.