Combining simulation and virtual reality for enabling interoperable digital twins in collaborative human–robot workspaces

The spread of new technologies and concepts, such as Digital Twin (DT), Virtual Reality (VR) and Human–Robot Collaboration (HRC), offers unprecedented opportunities but is also posing great new challenges within the manufacturing sector. This paper presents the design and development of a novel IT solution, which includes a Real-Time Virtual Simulation (RTVS) Module and an Interactive Virtual Reality Environment (IVRE) Module, which are part of a DT Module. Its main novelty consists in being interoperable and at the same time being able to faithfully model human and robot actions, conduct ergonomic analyses and measure working times. Interoperability is guaranteed by the adoption of the FIWARE/FIROS paradigm and websockets. The proposed IT solution is implemented and validated in an assembly system of an automotive company in the context of the European project “FlExible assembLy manufacturIng with human-robot Collaboration and digital twin modEls” (FELICE). Key findings of this research work include (1) the ability to conduct numerical simulations to compare different HRC scenarios and predict productivity improvements before physical implementation; (2) efficiency assessments that help identify optimal HRC configurations to enhance operator ergonomics and (3) generally positive user feedback, with identification of directions for future developments and improvements.