# Virtual Reality and Digital Twins for Catastrophic Failure Prevention in Industry 4.0
## 2 Materials and Methods
### Methodological Proposal
In addition, the early detection of abnormal operating conditions decreases unexpected down-time, generating operational savings and improving the overall safety of industrial facilities [17]  
Once the analyses of Step 1 are completed, where the need to integrate new technologies and sensors into the equipment is evaluated, in addition to considering and building maintenance plans, and after the implementation of the digital twin in Step 2, the last step is the implementation of an early warning system (EWS) based on the capture and processing of real-time information from the sensors installed in the physical equipment in order to functionally integrate all the technologies used and to allow different types of scenarios and conditions to be simulated. This system allows users to detect anomalous conditions in early stages, generating immediate alerts that can be visual and/or audible depending on the criticality of the detected conditions. Its objective is to complement and optimize predictive maintenance strategies and the continuous supervision and training of operating personnel [19]. The justification for implementing an EWS in the industrial context is due to the imperative increase in operational safety and the need to increase the ability to react to potentially catastrophic events. The integration of digital technologies such as advanced sensors, digital twins and virtual reality allows the early detection of operational deviations before they become critical faults, generating proactive responses that reduce unplanned downtime and increase occupational safety [19]. In this sense, the proposed system combines the use of a PLC for the direct acquisition of sensory data on key parameters (e.g., temperature, vibrations, flow or pressure), and uses platforms such as Node-RED as middleware that performs the function of managing the processing of these data in real time. The processed data is then simultaneously transmitted to Blynk for its remote display in the Unity graphics engine, where it is plotted on a digital twin. This application allows the easy visualization of operational values and the detection of anomalies in their early stages [20]. Node-RED is especially relevant in this integration, acting as an intermediary tool that facilitates efficient and fluid communication between the physical sensors (through the PLC) and the digital monitoring and alerting systems (Unity and Blynk). This platform not only processes and injects the data but also allows the generation of specific flows graphically that can be easily programmed to trigger automatic alarms when the sensorized values exceed the established thresholds [21]. Blynk functions as a means of direct communication with Unity about critical events in the production process or equipment status. The inclusion of visual and audible signals allows operators to act in a timely manner in the event of abnormal conditions before they lead to major damage or risk situations [16]. Unity, as the development platform for the VR environment, allows the immersive and dynamic visualization of the sensorized parameters in the exact location of the equipment within the digital twin. Thus, operators can intuitively visualize which sensors are indicating risk conditions, as well as have the possibility of observing the warnings that are presented at the moment a fault emerges or even before, improving the response capacity to these situations. In addition, virtual reality facilitates the simulation of these possible fault scenarios, strengthening the education and training of operating personnel without any real associated risk [18]. Finally, the effective implementation of early warning systems based on the integration of technologies such as virtual reality and the real-time monitoring of operational parameters will allow all types of industry to move towards an intelligent operation and maintenance model, thus increasing the efficiency and safety in their production processes and strengthening the essential principles of Industry 4.0 [22].