Digital Twin-Based Multimodal Condition Monitoring of Asynchronous Motors
Jiang Lingge
School of Information and Communication Engineering, University of Electronic Science and Technology of China, High-Tech Zone (West), Chengdu 611731, China.
The objective of this work is to propose and demonstrate a multimodal digital twin framework for the condition monitoring of the robotic automation cell in the edge-to-cloud. This system is comprised of a Robotic platform of 3 conveyors, CoppeliaSim model and an edge monitoring module on a Nano 33 BLE Sense development board Revision II. It was tested on the induction motor at 1500, 1200 and 900 RPM (revolutions per minute) with no-load and with no-disturbance. The tri-axial vibration and acoustic data were captured at 1 kHz and the temperature was experimented at 1 Hz for 60 s at each speed. Vibration distributions, acoustic Mel spectrograms and temperature trends were investigated. The results reveal multimodal fluctuations depending on the speed and could serve as a reference for future anomaly detection and predictive maintenance in robotic production systems based on AI.
O. Merkt, “Predictive models for maintenance optimization: An analytical literature survey of industrial maintenance strategies,” Lecture Notes in Business Information Processing, pp. 135–154, Jan. 2020, doi: 10.1007/978-3-030-43353-6_8.
J. Fernandes, J. Reis, N. Melão, L. Teixeira, and M. Amorim, “The role of Industry 4.0 and BPMN in the arise of condition-based and predictive maintenance: A case study in the automotive industry,” Appl. Sci., vol. 11, no. 8, Art. no. 3438, Apr. 2021, doi: 10.3390/app11083438.
M. Ayyat, M. Osman, and T. Nadeem, “Opportunities and challenges of foundation models in industrial manufacturing,” IEEE Access, vol. 13, pp. 138745–138775, 2025, doi: 10.1109/ACCESS.2025.3589777.
V. Rossi, T. Caffi, I. Salotti, and G. Fedele, “Sharing decision-making tools for pest management may foster implementation of integrated pest management,” Food Security, vol. 15, no. 6, pp. 1459–1474, Oct. 2023, doi: 10.1007/s12571-023-01402-3.
A. Mayr et al., “Electric Motor Production 4.0—Application potentials of Industry 4.0 technologies in the manufacturing of electric motors,” in Proc. 8th Int. Electric Drives Production Conf. (EDPC), 2018, pp. 1–13, Dec. 2018, doi: 10.1109/EDPC.2018.8658294.
R. R. Kumar, M. Andriollo, G. Cirrincione, M. Cirrincione, and A. Tortella, “A comprehensive review of conventional and intelligence-based approaches for the fault diagnosis and condition monitoring of induction motors,” Energies, vol. 15, no. 23, Art. no. 8938, Nov. 2022, doi: 10.3390/en15238938.
B. L. C., S. G. A., B. J. N., and D. M. A. V., “An explainable artificial intelligence approach for unsupervised fault detection and diagnosis in rotating machinery,” Mech. Syst. Signal Process., Art. no. 108105, 2022, doi: 10.1016/j.ymssp.2021.108105.
H. Liu, J. Zhou, Y. Zheng, W. Jiang, and Y. Zhang, “Fault diagnosis of rolling bearings with recurrent neural network-based autoencoders,” ISA Trans., vol. 77, pp. 167–178, Apr. 2018, doi: 10.1016/j.isatra.2018.04.005.
M. H. Rony et al., “Deep learning and few-shot learning-enabled machine health monitoring for rotating machinery: A critical review of vibration-based fault diagnosis, prognostics, and industrial deployment,” Qual. Reliab. Eng. Int., Jul. 2026, doi: 10.1002/qre.70302.
D.-T. Hoang and H.-J. Kang, “A survey on deep learning-based bearing fault diagnosis,” Neurocomputing, vol. 335, pp. 327–335, Nov. 2018, doi: 10.1016/j.neucom.2018.06.078.
D. C. Swanson, “A general prognostic tracking algorithm for predictive maintenance,” in Proc. IEEE Aerospace Conf., vol. 6, 2001, pp. 2971–2977, 2002, doi: 10.1109/AERO.2001.931317.
S. Ayvaz and K. Alpay, “Predictive maintenance system for production lines in manufacturing: A machine learning approach using IoT data in real-time,” Expert Syst. Appl., vol. 173, Art. no. 114598, Jan. 2021, doi: 10.1016/j.eswa.2021.114598.
M. Kannapinn, D. Dorer, M. Schäfer, and O. Weeger, “Digital twins for autonomous thermal food processing: A model predictive control study with reduced-order models of augmented neural ordinary differential equation type,” J. Food Eng., vol. 410, Art. no. 112918, Dec. 2025, doi: 10.1016/j.jfoodeng.2025.112918.
M. Ali, S. Giri, Q. Yang, and S. Liu, “Digital twin-enabled real-time control for robot arm-based manufacturing via reinforcement learning,” J. Intell. Manuf., Nov. 2025, doi: 10.1007/s10845-025-02728-9.
R. Wang et al., “Cloud-edge collaborative industrial robotic intelligent service platform,” in Proc. IEEE Int. Conf. Joint Cloud Comput., 2020, pp. 71–77, Aug. 2020, doi: 10.1109/JCC49151.2020.00020.
M. Singh et al., “Unity and ROS as a digital and communication layer for digital twin application: Case study of robotic arm in a smart manufacturing cell,” Sensors, vol. 24, no. 17, Art. no. 5680, Aug. 2024, doi: 10.3390/s24175680.
J. D. Choi, S.-H. Choi, M. Y. Kim, I. Lee, S. Lee, and B. H. Kim, “AI and digital twin federation-based flexible safety control for human–robot collaborative work cell,” IEEE Access, vol. 13, pp. 124037–124050, 2025, doi: 10.1109/ACCESS.2025.3586121.
Y. Gao, F. J. Muzzio, and M. G. Ierapetritou, “A review of the residence time distribution (RTD) applications in solid unit operations,” Powder Technol., vol. 228, pp. 416–423, Jun. 2012, doi: 10.1016/j.powtec.2012.05.060.
G. Simion, A. Filipescu, D. Ionescu, and A. Filipescu, “Cloud/VPN-based remote control of a modular production system assisted by a mobile cyber–physical robotic system—Digital twin approach,” Sensors, vol. 25, no. 2, Art. no. 591, Jan. 2025, doi: 10.3390/s25020591.
Z. Yin, A. Montello, C. D. Carter, W. R. Lempert, and I. V. Adamovich, “Measurements of temperature and hydroxyl radical generation/decay in lean fuel–air mixtures excited by a repetitively pulsed nanosecond discharge,” Combust. Flame, vol. 160, no. 9, pp. 1594–1608, Apr. 2013, doi: 10.1016/j.combustflame.2013.03.015.
CRediT Author Statement
The author reviewed the results and approved the final version of the manuscript.
Acknowledgements
The authors sincerely thank the faculty members for their valuable guidance, suggestions, and continuous encouragement.
Funding
No funding was received to assist with the preparation of this manuscript.
Ethics Declarations
Conflict of interest
The authors have no conflicts of interest to declare that are relevant to the content of this article.
Availability of Data and Materials
Data sharing is not applicable to this article as no new data were created or analysed in this study.
Author Information
Contributions
All authors have equal contribution in the paper and all authors have read and agreed to the published version of the manuscript.
Corresponding Author
Jiang Lingge
School of Information and Communication Engineering, University of Electronic Science and Technology of China, High-Tech Zone (West), Chengdu 611731, China.
Open Access This article is licensed under a Creative Commons Attribution NoDerivs is a more restrictive license. It allows you to redistribute the material commercially or non-commercially but the user cannot make any changes whatsoever to the original, i.e. no derivatives of the original work. To view a copy of this license, visit: https://creativecommons.org/licenses/by-nc-nd/4.0/
Cite this Article
Jiang Lingge, “Digital Twin-Based Multimodal Condition Monitoring of Asynchronous Motors”, Elaris Computing Nexus, pp. 156-166, 2026, doi: 10.65148/ECN/2026013.