Digital Twins at the Edge
As industrial operations become more connected and data-driven, organizations need better ways to understand what is happening across their physical assets in real time. Digital twins help bridge this gap by creating virtual representations that reflect real-world conditions. While some digital twins are developed for design and simulation, operational digital twins maintain an active connection with deployed assets through real-time data. This gives organizations greater visibility into asset performance and system behavior.
For operational digital twins, data must move quickly from industrial equipment and sensors into the systems that can use it. Edge computing brings this processing closer to the physical asset, allowing data to be collected and processed locally while reducing dependence on the cloud. This is especially important for industrial applications where low latency and timely response are critical.
Once the processed data reaches the digital twin, it provides an updated view of the physical system and supports insights that can inform decisions and actions. As conditions change, new operational data becomes available and the digital twin continues to update. This continuous exchange between the physical and digital worlds creates the digital twin feedback loop.
How Does the Digital Twin Feedback Loop Work?
To break down the digital twin feedback loop, we can look at the role each stage plays as data moves between the physical and digital worlds:
Physical Assets → Sensors & Data → Edge Computing → Digital Twin → Insights & Decisions → Action → Physical Assets
- Physical Assets & Sensors: Sensors and connected devices capture operating data such as temperature, vibration, pressure, speed, and energy consumption. Cameras can also provide visual data for machine vision applications.
- Edge Computing: Data is collected and processed close to the machine before relevant information is sent to the digital twin.
- Digital Twin: The virtual representation updates based on real-world operating data, providing visibility into the current state and performance of the physical asset.
- Insights & Decisions: Operational data can reveal changes that require attention, such as abnormal vibration, rising temperatures, or opportunities to adjust machine parameters.
- Action: The resulting decision is applied to the physical environment. Sensors capture the new conditions, and the process begins again.
This closes the feedback loop and keeps the digital twin continuously connected to changes in the physical world.
What Role Does Edge Computing Play in a Digital Twin?
Edge computing is what brings digital twin processing closer to the physical world. Instead of relying entirely on remote cloud infrastructure, edge computers process operational data near the machines and equipment generating it. But operating at the edge also introduces hardware requirements that conventional PCs are not typically designed to address.
|
Requirement |
Industrial Edge Computer |
Conventional PC |
|
Real-Time Edge Processing |
Processes operational data close to machines and sensors |
Typically designed for general-purpose computing |
|
Industrial Connectivity |
Supports industrial I/O such as COM, LAN, USB, CAN, and application-specific interfaces |
Primarily supports standard consumer/commercial interfaces |
|
Expansion & AI Acceleration |
Supports PCIe, M.2, GPUs, and AI accelerators for application-specific workloads |
Expansion depends on the PC form factor and platform |
|
Rugged Operation |
Designed for temperature variation, shock, vibration, and demanding industrial environments |
Designed primarily for controlled indoor environments |
|
Power Input |
Can support wide-range DC power and industrial power requirements |
Typically designed around standard AC power |
|
Continuous Deployment |
Designed for long-term operation near physical assets |
Designed primarily for office or general computing environments |
|
Remote Management |
Can support in-band and out-of-band management for remote monitoring and recovery |
Remote management capabilities vary by platform |
These requirements show why edge computing is an important part of the digital twin architecture. To support the complete feedback loop, the hardware must be able to connect, process, accelerate, and operate at the edge.
How Premio Powers Digital Twins at the Edge
With over 35 years of experience in rugged edge computing, Premio develops solutions designed to meet the performance and reliability demands of real-world digital twin deployments. These solutions bring together the essential capabilities needed to connect, process, accelerate, and operate throughout the digital twin feedback loop.
CONNECT: Connect Physical Assets and Data Sources
Comprehensive I/O
Premio’s industrial edge computers and LLM edge AI servers provide comprehensive onboard I/O for connecting physical equipment to the digital twin environment. With support for COM, CAN, USB, LAN, and digital I/O, they can connect to a wide range of sensors and industrial devices while supporting the continuous flow of operational data.
For deployments with specific installation requirements, Premio also offers one-sided I/O edge computers, such as the VCO and KCO Series. By placing key connections on one side, the design simplifies cable routing and system integration, especially in space-constrained industrial environments.
Modular EDGEBoost I/O
When additional connectivity is required beyond the onboard I/O, Premio EDGEBoost I/O (EBIO) provides a modular way to expand an industrial computer. Users can mix and match EDGEBoost I/O modules alongside the fixed onboard I/O to meet specific deployment requirements. Available options include:
- LAN & PoE: Add RJ45 or M12 LAN/PoE ports for cameras, sensors, and other networked devices, with 10GbE options for higher-bandwidth applications.
- USB & Serial: Add USB or COM ports for additional industrial devices and peripherals.
- M.2 Expansion: Add 5G connectivity, NVMe storage, or AI acceleration based on application requirements.
EDGEBoost I/O can also add out-of-band (OOB) management to supported Premio industrial computers, providing a dedicated interface for remote monitoring and recovery.
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PROCESS: Process Operational Data at the Edge
Multiple Processor Architectures
Digital twin workloads can vary significantly in processing requirements. Premio offers computing solutions powered by Intel, AMD, and NVIDIA Jetson processors, providing options for different levels of performance and power consumption.
- Intel: From power-efficient Intel Atom processors to Intel Core, Core Ultra, and Xeon processors for more demanding edge workloads.
- AMD: Select solutions support AMD Ryzen processors for high-performance multi-core computing.
- NVIDIA Jetson: Integrated CPU and GPU computing for edge AI inference, computer vision, and other accelerated workloads.
Premio works closely with leading processor technology providers as an Intel Prestige Partner, NVIDIA Elite Partner, and AMD Embedded Partner. These partnerships support Premio’s ability to integrate the latest computing technologies across its industrial edge computing portfolio.
ACCELERATE: GPU-Accelerated Computing at the Edge
As digital twin workloads become more demanding, some applications require additional computing power beyond CPU processing alone. Discrete GPUs provide the parallel processing needed for workloads such as 3D visualization, simulation, AI inference, and computer vision, bringing high-performance acceleration directly to the edge.
Discrete GPU Acceleration
Premio offers industrial GPU computers and rugged edge AI workstations designed to support NVIDIA professional GPUs for demanding digital twin workloads. Key capabilities include:
- Latest NVIDIA GPU Architectures: Support for NVIDIA professional GPUs, including the latest RTX PRO Blackwell architecture.
- Flexible GPU Configurations: Options range from low-profile GPUs to full-height, full-length (FHFL) dual-slot GPUs for different performance requirements.
- Dual-GPU Support: Select Premio computers support up to two FHFL dual-slot GPUs for compute-intensive workloads.
- High GPU Power Budget: Select Premio GPU computers, including the VCO-6000 and KCO-6000 Series, support up to a 600W GPU power budget for high-performance GPU configurations.
These GPU options provide the acceleration needed for compute-intensive digital twin applications while keeping processing close to where operational data is generated.
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OPERATE: Maintain Reliable Edge Operations
Rugged Design
Keeping a digital twin running means the edge computer also needs to remain reliable in the physical environment where it is deployed. Premio industrial computers are built for demanding edge conditions, with rugged features designed to handle temperature changes, power fluctuations, shock, and vibration.
- Wide Operating Temperature: Operating temperature ranges reaching -20°C to 70°C for deployments exposed to extreme temperature conditions.
- Wide Power Input: 9–48VDC wide-range power input to accommodate varying industrial power requirements.
- Shock & Vibration Resistance: Designed and tested to MIL-STD-810H standards for shock and vibration resistance in demanding industrial environments.
- Industrial Certifications: UL, CE, and FCC certifications to support safety and compliance requirements for industrial deployments.
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Remote Management
For digital twin deployments across distributed or difficult-to-access locations, remote management helps keep edge computers connected, monitored, and recoverable while reducing the need for on-site service. Premio offers two remote management solutions for different operational needs:
- Premio EDGEBoost OOB: Provides hardware-level out-of-band management that operates independently from the operating system. Through a web-based GUI, users can access functions such as remote power control, scheduled power ON/OFF, Device Always ON, power status detection, and serial console access. Critical recovery functions remain accessible even when the operating system becomes unresponsive.
- Allxon Remote Management: Combines in-band monitoring and out-of-band recovery for distributed edge deployments. Capabilities include device alerts, log collection, OTA updates, GPU monitoring, remote commands, screenshots, and fleet provisioning, with OOB access available for hardware-level recovery.
Together, these solutions support both hardware-level recovery and broader remote device management, helping maintain uptime across digital twin deployments.
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Power Your Digital Twin with Premio
Turning a digital twin concept into a real-world deployment requires more than the right computing hardware. With more than 35 years of industrial computing experience, Premio helps customers bring solutions from development into demanding edge environments. From our headquarters in Los Angeles, California, we support projects throughout the development and deployment process, backed by global manufacturing capabilities.
Our ISO-certified facilities support consistent manufacturing quality, while NDAA/TAA-compliant options are available for projects with specific procurement requirements. Whether you are building a new operational digital twin or scaling an existing deployment, Premio can provide the reliable edge computing foundation to support it. Ready to power your next digital twin deployment? Talk to a Premio expert.