5G-Connected AAS Digital Twin

Objective

Demonstrate how Asset Administration Shell digital twins, integrated with 5G private network infrastructure, enable dynamic reconfiguration and real-time monitoring of smart manufacturing assembly lines — and illustrate how AAS-aligned interoperability standards lower the barrier to digital twin adoption for small and medium-sized manufacturers.

Value

By establishing AAS as a standardized digital twin model for 5G-connected manufacturing assets, this showcase advances the broader goal of vendor-neutral, interoperable smart factory ecosystems — enabling manufacturers of all sizes to reconfigure, monitor, and scale production lines.

Digital Twin Role

By creating standardized AAS instances that digitally represent each physical machine and process node on the assembly line — including their 5G network configuration parameters, operational data, and process metadata — the digital twin enables autonomous network reconfiguration, real-time production monitoring, and structured data exchange via OPC UA.

5G-Connected AAS Digital Twin for Smart Manufacturing Assembly

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Problem:

Manufacturing industries — particularly automotive components and discrete assembly sectors — face mounting challenges as they adapt production lines to meet increasingly variable demand for different product types. Traditional assembly line infrastructure relies on fixed LAN cabling and proprietary PLC communication protocols, making even routine line modifications time-consuming, costly, and error-prone. When a new machine is introduced or a line reconfigured, technicians must manually rewire network connections, reconfigure 5G devices individually, and renegotiate software-level integrations — creating significant setup delays and downtime. Small and medium-sized manufacturers bear a disproportionate burden, as they lack the dedicated IT resources and communication software investment that larger enterprises can absorb. Without a standardized, flexible approach to machine communication and network management, factories cannot achieve the responsiveness or scalability that modern smart manufacturing demands.

Solution:

An Asset Administration Shell (AAS)-based digital twin architecture connected to a 5G private network, integrating Programmable Logic Controllers (PLCs), OPC UA data bridging, and a 5G Multi-access Edge Computing (MEC) platform to enable dynamic network reconfiguration and real-time production line monitoring. The architecture operates through an ICT Manufacturing Operating System (MOS) middleware layer — hosted at the edge — that maintains a structured AAS repository, performs continuous data gathering and analysis, and delivers cloud/edge management across the production environment. The digital twin layer simplifies communication and coordination among all line assets in alignment with AAS standards, making assembly line changes faster and less dependent on proprietary software. Key capabilities include:

AAS-based machine identity and network management. Each production asset is represented by a standardized AAS instance containing its 5G network parameters, enabling automated configuration and reconfiguration without manual individual device allocation.
5G private network connectivity. A dedicated 5G Core and Radio Access Network (RAN) replaces fixed LAN cabling on the shop floor, providing low-latency, high-bandwidth wireless connectivity to field devices, Autonomous Mobile Robots (AMRs), and vision camera systems.
OPC UA data bridging. PLC data transmitted via proprietary protocols is converted to OPC UA format through a 5G-linked bridge device, enabling seamless interoperability between legacy equipment and the AAS/MOS platform.
2D/3D production line monitoring. MOS services deliver real-time dashboards and 3D rendering of the production environment, with automated 5G network settings management and a live network monitoring interface.

Outcomes:

Reduced line changeover time: Eliminating manual LAN rewiring and individual device allocation through AAS-managed 5G reconfiguration significantly reduces setup time when new machines are added or production lines are modified.
Cost efficiency: Removing dedicated LAN infrastructure and proprietary 5G communication software requirements lowers both capital and operational expenditure for line modifications.
Interoperability and standardization: AAS-based integration establishes a standard data reference model for 5G devices and manufacturing communications, enabling structured data exchange across heterogeneous industrial systems.
Real-time operational visibility: Continuous OPC UA data streaming from PLCs to the AAS repository, combined with 2D/3D dashboards, gives operators live insight into production line status and performance aligned with AAS compliance guidelines.

Key Player:

Gyeongnam Technopark is a regional innovation and technology support organization based in South Korea's Gyeongnam province, focused on advancing smart manufacturing capabilities for industrial enterprises. The organization develops and pilots applied technology platforms — including digital twin and 5G network solutions — to support the competitiveness of local manufacturers and their supply chain partners, with particular emphasis on small and medium-sized enterprises.