A modular edge controller for digital twins connects real-world systems to simulations, creating smarter, data-driven engineering environments.

In modern engineering, digital twins are changing how systems are designed, tested, and optimized. A digital twin is a virtual model of a physical system that mirrors its real-time behavior through continuous data exchange. GOcontroll’s Moduline platform, can be used as a modular edge controller platform for digital twins – bridging the gap between machine and software by collecting live sensor data and feeding it directly into simulation environments like MATLAB Simulink or Node-RED.

A digital twin depends on accurate, live data to stay synchronized with its physical counterpart. This data comes from sensors, actuators, and process controllers operating at the edge—the layer closest to the physical equipment.

An edge controller for digital twin applications must:

• Collect data from sensors in real time.

• Perform local processing to reduce latency.

• Transmit cleaned and synchronized data to simulation platforms.

• Support feedback control from virtual models to real systems.

GOcontroll’s Moduline controllers meet these requirements through a robust modular architecture that adapts to any type of industrial or research environment.

The GOcontroll Moduline Mini and Moduline IV serve as the perfect bridge between physical and digital systems. Each controller is built on an NXP i.MX 8M processor, running Linux for flexible integration with open-source and commercial software tools.

Key benefits for digital twin integration:

• Real-time data processing using modular I/O channels.

• CAN, Ethernet, and RS232 interfaces for machine communication.

• Simulink and Node-RED compatibility for code generation, data visualization and simulation feedback.

• Cloud connectivity for distributed or multi-site setups.

This setup allows engineers to simulate performance, validate control logic, and predict failures using real-world input—without interrupting operations.

The Moduline controllers seamlessly send live data into digital twin software environments such as MATLAB Simulink, where it can be processed, visualized, and used for predictive modeling.

A typical setup includes:

1. Sensors and modules gathering real-time values (temperature, pressure, vibration, etc.).

2. Moduline edge controller processing and formatting data locally.

3. Communication layer sending data over Ethernet or MQTT to the digital twin model.

4. Simulation software using that data for model updates, performance tracking, or anomaly detection.

This feedback loop creates a living model that evolves alongside the physical system, enabling faster decision-making and early fault detection.

Every digital twin setup is different—ranging from small laboratory test rigs to large industrial systems. The Moduline platform’s modular design lets engineers build exactly what they need:

• Input modules for sensors and analog signals.

• Output modules for control and actuation.

• Communication modules for network and fieldbus integration.

By using the same base controller, multiple digital twin nodes can be deployed and customized easily, keeping development and maintenance simple.

Unlike traditional data loggers, Moduline controllers are designed for real-time edge computing. Local processing ensures that only essential, validated data is transmitted to the simulation environment, reducing cloud load and improving responsiveness.

With its open Linux environment, engineers can:

• Run custom scripts or AI algorithms at the edge.

• Preprocess sensor data for higher accuracy.

• Synchronize time-series data with simulation clocks.

• Use Node-RED dashboards for instant visualization.

This makes the Moduline Mini not only a bridge to the digital twin—but also a smart processor in its own right.

As industries move toward predictive maintenance and adaptive control, connecting physical assets to digital twins becomes essential. GOcontroll’s edge controller for digital twin solutions empower engineers to create interactive, data-driven systems that evolve continuously with real-world performance.

From prototyping to production, the Moduline platform enables you to collect, compute, and connect—all from one modular controller. It’s the practical foundation for bringing the digital twin to life at the edge.