Application of augmented reality-based digital twin approaches: a case study to industrial equipment

Technology is constantly evolving, changing how industries work by making processes more efficient. This shift, known as Industry 4.0, connects the real and digital worlds, allowing devices, people, and systems to communicate through the Internet. Key technologies include Internet of Things, big data, additive manufacturing, artificial intelligence, machine learning, augmented reality, and digital twins. This paper focuses on researching and implementing enabling technologies of Industry 4.0 by illustrating the design of DT models and AR experiences of a test bench with a motorized planetary gearbox. The case study starts from the CAD realization and assembly of all the components by using PTC Creo Parametric. Then, sensors are installed and connected to data acquisition devices to acquire and monitor input and output parameters of the system. Finally, AR experiences are developed using Vuforia Studio starting from CAD models of real components. The AR experience showed when the gearbox was not working properly, with the output shaft running about 13% slower than expected. Because of this, the gearbox was disassembled, and the inspection found some rusted parts inside. This paper presents the steps to create a DT model and AR interface using affordable hardware and software. The project shows how these tools can be used in industrial settings and education for activities such as hands-on learning, plant design, real-time monitoring, predictive maintenance, remote support, and sharing knowledge.