12.05.2025
Digital Twin at Balluff
An Interview with Philippe Komma
The digital twin is revolutionizing industrial production and plant development. Philippe Komma from Balluff provides insights into how companies can plan and optimize their production more efficiently, the benefits it offers, and the developments that will shape the future.
Mr. Komma, how did you come to Balluff? And what positions have you held here before focusing on the topic of "Digital Twin"?
I have a long-standing connection with Balluff. About ten years ago, I started as a developer at Matrix Vision, a subsidiary of Balluff. Initially, I worked in the Smart Vision area and developed software. After a few years, I took on the role of Product Owner, acting as a bridge between product management and the development team. At that point, I was already deeply involved with IoT interfaces.
And how did you get involved in the topic of "Digital Twin"?
The topic of digital twins was already being discussed as a potential project before my time at Balluff. About a year and a half ago, I transitioned into the role of Product Manager at Balluff, where I took over the digital twin project.
The term "digital twin" is widely used today. Could you explain how Balluff defines it?
Of course. The term digital twin is used quite broadly. For us, a digital twin is a digital representation that maps a product or process throughout all lifecycle phases. This could be a hardware component, such as an RFID module, or an entire system. The key aspect is that it is a digital representation – something that can be visualized on a computer and reflects the entire lifecycle, from the initial sketch to discontinuation. At Balluff, we understand it as a 1:1 counterpart of our physical products in the digital world, mirroring their condition and behavior in real-time.
What specific benefits do customers gain from digital twins?
One key application is virtual commissioning. This allows our customers to fully simulate and test their machines and systems digitally – before any hardware is available. This means that even in the early stages of development, potential improvements and optimizations can be identified. It saves time and costs.
How does Balluff provide digital twins to customers?
We use the simulation environment of our cooperation partner. Through their simulation platform, customers can utilize digital behavior models of our products. Via the "Twin Store," a platform similar to an app store, customers can directly access the digital behavior models of the specific products they need for their applications. This includes not just the components themselves but also their internal properties and protocols. We can represent every IO-Link component, every sensor, or even a Smartlight.
So Balluff collaborates with partners to provide this technology?
Exactly, our partner here is ISG-virtuos. Their simulation environment makes digital twins more flexible. This ensures that our customers can use the models in all common simulation frameworks and for various applications. ISG also provides the Twin Store for customers.
What technology powers Balluff’s digital twins?
Our digital twins consist of behavior models. Take an RFID sensor, for example: It can write data onto an RFID tag or read data from it. The digital behavior model replicates this virtually, so the machine's control system believes it is communicating with a real sensor. This enables simulation and testing of complete processes and systems on a computer.
Are there specific customer projects that demonstrate how digital twins are used in practice?
Yes, our pilot customer Teamtechnik is successfully using our digital twins. The feedback shows that this technology provides real added value by enabling realistic simulation of machine processes while reducing costs. Teamtechnik particularly appreciates the flexibility and adaptability of digital twins to their individual requirements.
hat challenges does this technology solve for your customers?
Our customers often face the challenge of planning complex systems as efficiently as possible and getting them up and running quickly. With digital twins, they can test in advance whether all components work together seamlessly before physical assembly. This minimizes downtime and increases planning reliability. We are seeing particularly strong interest in virtual commissioning from the automotive industry, which is also driving this topic forward.
Companies like BMW and Daimler now require machine and plant manufacturers to provide digital models of their systems. These must be available before physical counterparts can be placed. Without digital twins, we would not be competitive in many projects.
Was there a moment in your career that significantly shaped you and changed your perspective on technology and innovation?
I can recall three key moments in my career. The first was in my youth when I discovered my passion for computer graphics and programming. My parents enrolled me in a programming course at school, which sparked my interest in technology. The second moment was at my previous employer, BMW, where I developed firmware for vehicles. Sitting in a car and experiencing software that I had helped create was a fascinating feeling. The third moment is the rapid development of AI technology in recent years, particularly generative AI. This technology enables content such as images or music to be generated from just a few inputs, and I see great potential in how it could enrich Balluff’s communication with our customers.
What motivates you in your work, and what do you appreciate about Balluff's corporate culture?
What drives me the most is the variety of topics I get to work on. In the Industry 4.0 sector, I have a lot of creative freedom to shape my projects. I also want to highlight Balluff’s corporate culture. The open and friendly atmosphere, even when discussing controversial topics, creates a great working environment. There are also many opportunities to exchange ideas with colleagues and customers internally and externally, making my work even more rewarding.
What are your plans for the future? And are there any regulatory requirements Balluff must consider?
Development remains dynamic. We anticipate regulatory requirements in the form of a digital product passport. This could become mandatory in the future and include information such as a product’s CO2 footprint. We take these requirements very seriously at Balluff and are already preparing to provide our customers with the necessary flexibility to meet them when the time comes.
How do digital twins impact Balluff’s business model?
We see digital twins as a support tool for our hardware products rather than a standalone revenue generator. The digital twin is an enabler for our core products and strengthens our profile. In the long run, however, digital twins will play a crucial role in positioning us as an innovative partner in the Industry 4.0 sector.
Do you see other applications for digital twins beyond the classic industrial use cases?
Digital twins offer many possibilities beyond just simulating production processes. For example, they can structure data for different target groups, such as product managers or developers. A data package can be presented differently depending on the use case, significantly increasing efficiency. I also see great potential in the combination of digital twins and AI in the future, such as language models that help customers quickly retrieve information about their products.
Thank you, Mr. Komma, for these fascinating insights!
Thank you! I’m happy to introduce this topic, and I’m looking forward to showcasing our digital twins live at the next trade fair.
