Industrial automation laboratories often face limitations related to restricted access to industrial equipment, safety constraints, and limited scalability for hands-on experimentation. To address these challenges, this work proposes a real-time multi-layer Digital Twin architecture integrating a physical Siemens S7-1500 PLC, an immersive Unity-based virtual environment, HMI supervision, and IoT-enabled remote monitoring within a unified communication framework. The architecture is structured into physical, digital, and integration layers, enabling modular scalability and bidirectional synchronization between the physical process and its virtual representation through Ethernet TCP/IP communication. System performance was evaluated using synchronization metrics including communication latency, jitter, deterministic timing deviation, and event synchronization accuracy. Experimental results demonstrated stable PLC–Digital Twin communication with average latencies below 15 ms and jitter below 0.5 ms, ensuring reliable real-time interaction during continuous operation. A comparative evaluation with engineering students also showed improved learning conditions, achieving high perceived usability (SUS = 86/100) and reduced cognitive workload (NASA-TLX = 34/100). These results confirm the effectiveness of the proposed architecture as a scalable platform for Industry 4.0 training environments.
Ortiz et al. (2026) studied this question.