Bridging the Reality Gap in Digital Twins with Context-Aware, Physics-Guided Deep Learning

Digital twins (DTs) enable powerful predictive analytics, but persistent discrepancies between simulations and real systems--known as the reality gap--undermine their reliability. Coined in robotics, the term now applies to DTs, where discrepancies stem from context mismatches, cross-domain interactions, and multi-scale dynamics. Among these, context mismatch is pressing and underexplored, as DT accuracy depends on capturing operational context, often only partially observable. However, DTs have a key advantage: simulators can systematically vary contextual factors and explore scenarios difficult or impossible to observe empirically, informing inference and model alignment. While sim-to-real transfer like domain adaptation shows promise in robotics, their application to DTs poses two key challenges. First, unlike one-time policy transfers, DTs require continuous calibration across an asset's lifecycle--demanding structured information flow, timely detection of out-of-sync states, and integration of historical and new data. Second, DTs often perform inverse modeling, inferring latent states or faults from observations that may reflect multiple evolving contexts. These needs strain purely data-driven models and risk violating physical consistency. Though some approaches preserve validity via reduced-order model, most domain adaptation techniques still lack such constraints. To address this, we propose a Reality Gap Analysis (RGA) module for DTs that continuously integrates new sensor data, detects misalignments, and recalibrates DTs via a query-response framework. Our approach fuses domain-adversarial deep learning with reduced-order simulator guidance to improve context inference and preserve physical consistency. We illustrate the RGA module in a structural health monitoring case study on a steel truss bridge in Pittsburgh, PA, showing faster calibration and better real-world alignment.

State-of-the-Art Review: The Use of Digital Twins to Support Artificial Intelligence-Guided Predictive Maintenance

In recent years, predictive maintenance (PMx) has gained prominence for its potential to enhance efficiency, automation, accuracy, and cost-effectiveness while reducing human involvement. Importantly, PMx has evolved in tandem with digital advancements, such as Big Data and the Internet of Things (IOT). These technological strides have enabled Artificial Intelligence (AI) to revolutionize PMx processes, with increasing capacities for real-time automation of monitoring, analysis, and prediction tasks. However, PMx still faces challenges such as poor explainability and sample inefficiency in data-driven methods and high complexity in physics-based models, hindering broader adoption. This paper posits that Digital Twins (DTs) can be integrated into PMx to overcome these challenges, paving the way for more automated PMx applications across various stakeholders. Despite their potential, current DTs have not fully matured to bridge existing gaps. Our paper provides a comprehensive roadmap for DT evolution, addressing current limitations to foster large-scale automated PMx progression. We structure our approach in three stages: First, we reference prior work where we identified and defined the Information Requirements (IRs) and Functional Requirements (FRs) for PMx, forming the blueprint for a unified framework. Second, we conduct a literature review to assess current DT applications integrating these IRs and FRs, revealing standardized DT models and tools that support automated PMx. Lastly, we highlight gaps in current DT implementations, particularly those IRs and FRs not fully supported, and outline the necessary components for a comprehensive, automated PMx system. Our paper concludes with research directions aimed at seamlessly integrating DTs into the PMx paradigm to achieve this ambitious vision.

State-of-the-Art Review and Synthesis: A Requirement-based Roadmap for Standardized Predictive Maintenance Automation Using Digital Twin Technologies

Recent digital advances have popularized predictive maintenance (PMx), offering enhanced efficiency, automation, accuracy, cost savings, and independence in maintenance. Yet, it continues to face numerous limitations such as poor explainability, sample inefficiency of data-driven methods, complexity of physics-based methods, and limited generalizability and scalability of knowledge-based methods. This paper proposes leveraging Digital Twins (DTs) to address these challenges and enable automated PMx adoption at larger scales. While we argue that DTs have this transformative potential, they have not yet reached the level of maturity needed to bridge these gaps in a standardized way. Without a standard definition for such evolution, this transformation lacks a solid foundation upon which to base its development. This paper provides a requirement-based roadmap supporting standardized PMx automation using DT technologies. A systematic approach comprising two primary stages is presented. First, we methodically identify the Informational Requirements (IRs) and Functional Requirements (FRs) for PMx, which serve as a foundation from which any unified framework must emerge. Our approach to defining and using IRs and FRs to form the backbone of any PMx DT is supported by the track record of IRs and FRs being successfully used as blueprints in other areas, such as for product development within the software industry. Second, we conduct a thorough literature review spanning fields to determine the ways in which these IRs and FRs are currently being used within DTs, enabling us to point to the specific areas where further research is warranted to support the progress and maturation of requirement-based PMx DTs.