6G-Enabled Digital Twin Framework for Real-Time Cyber-Physical Systems: An Experimental Validation with Industrial Bearing Fault Detection

Abstract

Current Cyber-Physical Systems (CPS) integrated with Digital Twin (DT) technology face critical limitations in achieving real-time performance for mission-critical industrial applications. Existing 5G-enabled systems suffer from latencies exceeding 10ms, which are inadequate for applications requiring sub-millisecond response times, such as autonomous industrial control and predictive maintenance. This research aims to develop and validate a 6G-enabled Digital Twin framework that achieves ultra-low latency communication and real-time synchronization between physical industrial assets and their digital counterparts, specifically targeting bearing fault detection as a critical industrial use case. The proposed framework integrates terahertz communications (0.1-1 THz), intelligent reflecting surfaces, and edge artificial intelligence within a five-layer architecture. Experimental validation was conducted using the Case Western Reserve University (CWRU) bearing dataset, implementing comprehensive feature extraction (15 time and frequency domain features) and Random Forest classification algorithms. The system performance was evaluated against traditional WiFi-6 and 5G networks across multiple metrics, including classification accuracy, end-to-end latency, and scalability. It achieved 97.7% fault classification accuracy with 0.8ms end-to-end latency, representing a 15.6x improvement over WiFi-6 (12.5ms) and 5.25x improvement over 5G (4.2ms) networks. The system demonstrated superior scalability with sub-linear processing time growth and maintained consistent performance across four bearing fault categories (normal, inner race, outer race, and ball faults) with macro-averaged F1-scores exceeding 97%.