International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

Digital twin technology has rapidly evolved into a foundational pillar of modern engineering practice. By creating high-fidelity, data-driven virtual replicas of physical systems, digital twins enable continuous monitoring, predictive analytics, and advanced optimization throughout the lifecycle of assets. This extended article expands on the conceptual, technical, and practical dimensions of digital twins, providing deeper insights into architectures, data frameworks, integration strategies, real-world case studies, economic implications, and emerging research directions.

This study presents and validates a method for achieving positioning accuracy comparable to standalone GPS (approximately 10 m) using a proprietary Sigfox WiFi positioning system that transmits only two MAC addresses per message. Due to Sigfox’s severe payload limitations, conventional positioning attempts often fail or yield significant errors. Our approach introduces continuous scanning on the device to dynamically collect up to four MAC addresses, paired with meticulous backend analysis and filtering of MAC address quality using a custom Here API Validation Tool. The proposed method effectively addresses these limitations, demonstrating a 100% location acquisition rate and a median positional error of 19 meters, making it highly effective for both stationary and dynamic mobile tracking.

The aim of this work is to implement a wireless communication system for MEMS-based sensors within the framework of Internet of Things (IoT) applications, specifically in the context of Predictive Maintenance (PdM). The focus is placed on developing a functional prototype of a wireless sensor node that enables efficient data acquisition and transmission from commercially available MEMS vibration sensors. The solution leverages an ESP32 microcontroller for data handling and Wi-Fi communication, forming the basis of a scalable wireless sensor network (WSN). The project emphasizes their integration into a wireless system architecture suitable for industrial monitoring scenarios. This approach aims to demonstrate how low-cost MEMS sensors, when combined with IoT technologies, can contribute to accessible and modular condition monitoring solutions aligned with Industry 4.0.

The report analyzes the nature of the Internet of Things (IoT), presents a basic architectural model of IoT, and categorizes IoT according to various criteria. The most famous IoT security breaches are presented. The vulnerabilities that led to the security breaches and the scale and consequences of the impact of the breach are analyzed. Overview and analysis of IoT security breaches are the subject of this research. The main threats and vulnerabilities are systematize and the response of the world community is tracked

Many of the devices in the IoT group process personal information or information enabling profiling or revealing the identity of natural persons. Naturally, the question of the security of this information and compliance with the legal requirements for the protection of the personal data of natural persons and their inviolability arises. The study defined the main issues related to the protection of personal data, identified threats and risks to the security and privacy of information processed by IoT devices.

Industry 5.0 is the production model based on the concept of how people and machines can work together. Modern industry is focusing on collaboration between people, robots, and intelligent machines with the help of AI. The design and implementation of solutions, based on Industry 5.0 brings a new level with the latest achievements in Artificial Intelligence and especially the Generative AI, realized on top of the Open AI.
This paper focuses on implementing modern automation with the help of Open AI as a new concept to use AI as a SaaS, integrated with smart machines and robots, helping them to work in a human-like way. The research overviews the use cases and proposes a framework to build a smart solution based on Generative AI and cognitive robots, where integration between SaaS AI and smart machines is based on Cognitive Digital Twins. Research results also include prototypes of cognitive digital twins and its integration with intelligent machines.

Rapid progress in the field of industrialization and informatization methods has led to huge progress in the development of nextgeneration production technologies. The Internet of Things (IoT) is a pervasive technology, and now it is used in all areas of everyday life, from healthcare to technological production. The new industrial revolution began with connected technologies supported by the Internet of Things. However, the security of the Internet of Things is still an open question since in case of unauthorized access, data from sensors can be changed, for example, by a user with authorized access rights, which can lead to unforeseen consequences.

The emergence of Industry 4.0 has led to the development of high-tech solutions that influence a number of related activities. In the field of warehousing management, as an important element of logistics systems, there is also an impact that follows a certain model. Warehousing 4.0 and related developments have to be supported by a number of basic technologies for automatic identification, and technologies that represent intelligent connections to the real world. One of these is the Internet of Things (IoT), which is essentially based on many other solutions, including radiofrequency identification (RFID). The report presents some aspects of the application of RFID in the management of warehousing processes, and also reveals some basic practices of trade and manufacturing enterprises in that field. The study represents the results of a survey focused on warehousing management practices in Bulgaria. The results reveal some fundamental aspects of radiofrequency identification practices as a prerequisite for smart warehousing. The general findings are related to the relatively low and insufficient level of RFID technology usage in the field of warehousing.

This paper discusses a case of implementing Industry 4.0 solutions with existing legacy informational system in cement-producing factory. One of the main reasons the company wants to keep its existing ERP solution is because is too complex and cannot be ported to a contemporary computer architecture. The plant also needs to automate and modernize the process of loading their products, but the company management does not want to invest in modern computer servers and a new ERP system. That’s why they decided to implement a hybrid solution – a modern Industry 4.0 IoT devices with .NET client application using the existing legacy DEC Alpha as a server. Here, the required technologies used for developing that software solution are overviewed and all parts of the software solution are described. Finally, the benefits and effectiveness of such a hybrid software solution are shown.

Future of modern communication technologies of smart modern production systems is moving to wireless form of data transfer between devices. Thanks to use of smart devices that communicate within the network, we are talking about of interconnection of separate devices – Internet of Things (IoT). In connection with the implementation of standards Industry 4.0 in the manufacturing process together with IoT implementation into production process a new term is created – Industrial Internet of Things (IIoT). However, the implementation of this form of wireless communication brings some problems, mainly in field of safety and stability of data transfers. This paper provides a brief overview of the current state of the use of IIOT in industrial communication and production management and describes relationships to concepts such as cyber-physical systems and Industry 4.0. Part of the article is a proposal of communication scheme suitable for the implementation on model of modular production system (MPS).

The Smart Homes come rapidly into our everyday lives bringing comfort, security, help and many other benefits. The development of Information and Communication Technology and the advances in the applications based on Internet of Things emerged the appearing of more and more Smart Home solutions. The Smart Home System should implement default or custom integrated functions and intelligent self-adaptive methodology, based on the analysis of the habits, requirements and preferences of its inhabitants.
In this paper the authors consider the development of Android and Wi-Fi based remote control Smart Home System, which integrates the analysis of the survey of the everyday habits of the people. An analysis of habits of 64 surveyed people was made. The results can be taken into account during the process of defining the default integrated functions at the stage of designing a Smart Home. The presence, absence or approaching certain location by the people are included as elements of the Smart Home System.

Technology and innovations have powered the evolution of Industry4.0, the fourth industrial revolution.
State-of-the-art technologies such as the Internet of Things (IoT), cloud computing (CC), big data analytics (BDA), and artificial intelligence (AI) – all part of Industry4.0, have greatly stimulated the building industry. Digital Тwin is a significant enabler for Industry 4.0 initiatives. Within Industry 4.0, the amount of digital product information generated and collected over the entire lifecycle has been growing.
Although digital twins have been around for several decades, the rapid rise of the internet of things (IoT) is that they have become more widely considered as a tool of the future. Digital twins are getting attention because they also integrate things like artificial intelligence (AI) and machine learning (ML) to bring data, algorithms, and context together
A ―digital twin‖—or digital replica of a physical entity—can target building industry in several sub-areas:
– Facility management
– Product Lifecycle Management
– Smart Buildings
– Smart energy
All these areas are one giant step further by creating a Digital Twin — a virtual representation of real-world buildings that can be viewed and scrutinized in minute detail. This research describes business cases and best practices in design of IoT Solutions for building industry, powered by Digital Twins. A reference architecture and prototypes which demonstrate application of Digital Twins in Smart are created as a result of this study .This research is technology agnostic, but prototypes of sample solutions are considered in the context of Microsoft Azure (Azure solutions, covering Azure Digital Twins Service and Azure IoT Stack.)