Digital twin for locks - efficiency, safety and sustainable optimization

Digitalization does not stop at the waterway infrastructure. Modern locks must be operated efficiently, reliably and sustainably in order to meet the growing demands of freight and passenger traffic. A digital twin offers new opportunities to optimize lock operations, improve maintenance processes and reduce costs in the long term.

A digital twin is a virtual image of a lock that is fed with real-time data and enables detailed analyses. The continuous recording of sensor data allows operating processes to be tracked precisely, bottlenecks to be identified and optimization measures to be derived. The technology also enables predictive maintenance so that faults can be detected and rectified at an early stage before they lead to failures.

In addition to maintenance, the control of lock operation also plays a decisive role. Simulations can be used to run through different scenarios and adjustments can be made to make the flow at locks more efficient. This helps to reduce waiting times and make optimum use of the capacity of existing infrastructures.

The digital twin in the CRISTAL project

In the CRISTAL (Climate Resilient and Environmentally Sustainable Transport Infrastructure, with a Focus on Inland Waterways) research project, the digital twin is being used specifically to make inland waterway transport more efficient and sustainable. The project aims to use waterways more efficiently and improve their resilience to external influences.

A key aspect of CRISTAL is the integration of digital twins into the lock infrastructure. With the help of sensor data, for example, signs of wear on interlock mechanisms can be detected at an early stage and necessary maintenance measures can be initiated in good time. This prevents unplanned outages and minimizes operational interruptions.

In addition, the digital twin offers the opportunity to optimize the entire lock operation based on data. Through precise analyses, operators can make informed decisions to improve traffic flow, reduce energy consumption and use resources more efficiently. This not only contributes to cost savings, but also to the sustainable design of waterway logistics.

Why digital twins are indispensable in interlock technology

The implementation of digital twins offers lock operators numerous advantages. Maintenance costs can be reduced through targeted measures, as precise analyses help to determine the optimum time for repairs. At the same time, real-time monitoring and predictive maintenance significantly improve operational safety.

Another key aspect is increasing efficiency. By simulating workflows, optimization potential can be identified and processes adapted accordingly. As a result, bottlenecks can be avoided and throughput at locks can be increased. This is particularly relevant for the transportation of goods on waterways, which becomes more attractive thanks to efficient lock operations.

The digital twin also enables the long-term, sustainable use of existing infrastructure. Instead of having to rely on cost-intensive new buildings, existing systems can be optimized in a targeted manner and their service life extended.