A digital twin-driven human-robot collaborative assembly approach in the wake of COVID-19

Towards a Human-Centric Digital Twin for Human-Machine Collaboration: A Review on Enabling Technologies and Methods

With the intent to further increase production efficiency while making human the centre of the processes, human-centric manufacturing focuses on concepts such as digital twins and human-machine collaboration. This paper presents enabling technologies and methods to facilitate the creation of human-centric applications powered by digital twins, also from the perspective of Industry 5.0. It analyses and reviews the state of relevant information resources about digital twins for human-machine applications with an emphasis on the human perspective, but also on their collaborated relationship and the possibilities of their applications. Finally, it presents the results of the review and expected future works of research in this area.

Human-Centric Digital Twins in Industry: A Comprehensive Review of Enabling Technologies and Implementation Strategies

The last decade saw the emergence of highly autonomous, flexible, re-configurable Cyber-Physical Systems. Research in this domain has been enhanced by the use of high-fidelity simulations, including Digital Twins, which are virtual representations connected to real assets. Digital Twins have been used for process supervision, prediction, or interaction with physical assets. Interaction with Digital Twins is enhanced by Virtual Reality and Augmented Reality, and Industry 5.0-focused research is evolving with the involvement of the human aspect in Digital Twins. This paper aims to review recent research on Human-Centric Digital Twins (HCDTs) and their enabling technologies. A systematic literature review is performed using the VOSviewer keyword mapping technique. Current technologies such as motion sensors, biological sensors, computational intelligence, simulation, and visualization tools are studied for the development of HCDTs in promising application areas. Domain-specific frameworks and guidelines are formed for different HCDT applications that highlight the workflow and desired outcomes, such as the training of AI models, the optimization of ergonomics, the security policy, task allocation, etc. A guideline and comparative analysis for the effective development of HCDTs are created based on the criteria of Machine Learning requirements, sensors, interfaces, and Human Digital Twin inputs.

Towards next generation digital twin in robotics: Trends, scopes, challenges, and future

With the advent of Industry 4.0, several cutting-edge technologies such as cyber-physical systems, digital twins, IoT, robots, big data, cloud computation have emerged. However, how these technologies are interconnected or fused for collaborative and increased functionality is what elevates 4.0 to a grand scale. Among these fusions, the digital twin (DT) in robotics is relatively new but has unrivaled possibilities. In order to move forward with DT-integrated robotics research, a complete evaluation of the literature and the creation of a framework are now required. Given the importance of this research, the paper seeks to explore the trends of DT incorporated robotics in both high and low research saturated robotic domains in order to discover the gap, rising and dying trends, potential scopes, challenges, and viable solutions. Finally, considering the findings, the study proposes a framework based on a hypothesis for the future paradigm of DT incorporated robotics.

Study on the Applicability of Digital Twins for Home Remote Motor Rehabilitation

The COVID-19 pandemic created the need for telerehabilitation development, while Industry 4.0 brought the key technology. As motor therapy often requires the physical support of a patient's motion, combining robot-aided workouts with remote control is a promising solution. This may be realised with the use of the device's digital twin, so as to give it an immersive operation. This paper presents an extensive overview of this technology's applications within the fields of industry and health. It is followed by the in-depth analysis of needs in rehabilitation based on questionnaire research and bibliography review. As a result of these sections, the original concept of controlling a rehabilitation exoskeleton via its digital twin in the virtual reality is presented. The idea is assessed in terms of benefits and significant challenges regarding its application in real life. The presented aspects prove that it may be potentially used for manual remote kinesiotherapy, combined with the safety systems predicting potentially harmful situations. The concept is universally applicable to rehabilitation robots.

Digital Twin for a Collaborative Painting Robot

A collaborative painting robot that can be used as an alternative to workers has been developed using a digital twin framework and its performance was demonstrated experimentally. The digital twin of the automatic painting robot simulates the entire process and estimates the paint result before the real execution. An operator can view the simulated process and result with an option to either confirm or cancel the task. If the task is accepted, the digital twin generates all the parameters, including the end effector trajectory of the robot, the material flow to the collaborative robot, and a spray mechanism. This ability means that the painting process can be practiced in a virtual environment to decrease set costs, waste, and time, all of which are highly demanded in single-item production. In this study, the screen was fixtureless and, thus, a camera was used to capture it in a physical environment, which was further analyzed to determine its pose. The digital twin then builds the screen in real-time in a virtual environment. The communication between the physical and digital twins is bidirectional in this scenario. An operator can design a painting pattern, such as a basic shape and/or letter, along with its size and paint location, in the resulting procedure. The digital twin then generates the simulation and expected painting result using the physical twin's screen pose. The painting results show that the root mean square error (RMSE) of the painting is less than 1.5 mm and the standard deviation of RMSE is less than 0.85 mm. Additionally, the initial benefits of the technique include lower setup costs, waste, and time, as well as an easy-to-use operating procedure. More benefits are expected from the digital twin framework, such as the ability of the digital twin to (1) find a solution when a fault arises, (2) refine the control or optimize the operation, and (3) plan using historic data.

Collaborative approaches in sustainable and resilient manufacturing

In recent years, the manufacturing sector is going through a major transformation, as reflected in the concept of Industry 4.0 and digital transformation. The urge for such transformation is intensified when we consider the growing societal demands for sustainability. The notion of sustainable manufacturing has emerged as a result of this trend. Additionally, industries and the whole society face the challenges of an increasing number of disruptive events, either natural or human-caused, that can severely affect the normal operation of systems. Furthermore, the growing interconnectivity between organizations, people, and physical systems, supported by recent developments in information and communication technologies, highlights the important role that collaborative networks can play in the digital transformation processes. As such, this article analyses potential synergies between the areas of sustainable and resilient manufacturing and collaborative networks. The work also discusses how the responsibility for the various facets of sustainability can be distributed among the multiple entities involved in manufacturing. The study is based on a literature survey, complemented with the experience gained from various research projects and related initiatives in the area, and is organized according to various dimensions of Industry 4.0. A brief review of proposed approaches and indicators for measuring sustainability from the networked manufacturing perspective is also included. Finally, a set of key research challenges are identified to complement strategic research agendas in manufacturing.

The Development of a Digital Twin Framework for an Industrial Robotic Drilling Process

A digital twin is a digital representation of a physical entity that is updated in real-time by transfer of data between physical and digital (virtual) entities. In this manuscript we aim to introduce a digital twin framework for robotic drilling. Initially, a generic reference model is proposed to highlight elements of the digital twin relevant to robotic drilling. Then, a precise reference digital twin architecture model is developed, based on available standards and technologies. Finally, real-time visualisation of drilling process parameters is demonstrated as an initial step towards implementing a digital twin of a robotic drilling process.

Digital Twin-Driven Human Robot Collaboration Using a Digital Human

Advances are being made in applying digital twin (DT) and human–robot collaboration (HRC) to industrial fields for safe, effective, and flexible manufacturing. Using a DT for human modeling and simulation enables ergonomic assessment during working. In this study, a DT-driven HRC system was developed that measures the motions of a worker and simulates the working progress and physical load based on digital human (DH) technology. The proposed system contains virtual robot, DH, and production management modules that are integrated seamlessly via wireless communication. The virtual robot module contains the robot operating system and enables real-time control of the robot based on simulations in a virtual environment. The DH module measures and simulates the worker’s motion, behavior, and physical load. The production management module performs dynamic scheduling based on the predicted working progress under ergonomic constraints. The proposed system was applied to a parts-picking scenario, and its effectiveness was evaluated in terms of work monitoring, progress prediction, dynamic scheduling, and ergonomic assessment. This study demonstrates a proof-of-concept for introducing DH technology into DT-driven HRC for human-centered production systems.

A Survey on AI-Driven Digital Twins in Industry 4.0: Smart Manufacturing and Advanced Robotics

Digital twin (DT) and artificial intelligence (AI) technologies have grown rapidly in recent years and are considered by both academia and industry to be key enablers for Industry 4.0. As a digital replica of a physical entity, the basis of DT is the infrastructure and data, the core is the algorithm and model, and the application is the software and service. The grounding of DT and AI in industrial sectors is even more dependent on the systematic and in-depth integration of domain-specific expertise. This survey comprehensively reviews over 300 manuscripts on AI-driven DT technologies of Industry 4.0 used over the past five years and summarizes their general developments and the current state of AI-integration in the fields of smart manufacturing and advanced robotics. These cover conventional sophisticated metal machining and industrial automation as well as emerging techniques, such as 3D printing and human-robot interaction/cooperation. Furthermore, advantages of AI-driven DTs in the context of sustainable development are elaborated. Practical challenges and development prospects of AI-driven DTs are discussed with a respective focus on different levels. A route for AI-integration in multiscale/fidelity DTs with multiscale/fidelity data sources in Industry 4.0 is outlined.

Real-Time Learning and Recognition of Assembly Activities Based on Virtual Reality Demonstration

Teaching robots to learn through human demonstrations is a natural and direct method, and virtual reality technology is an effective way to achieve fast and realistic demonstrations. In this paper, we construct a virtual reality demonstration system that uses virtual reality equipment for assembly activities demonstration, and using the motion data of the virtual demonstration system, the human demonstration is deduced into an activity sequence that can be performed by the robot. Through experimentation, the virtual reality demonstration system in this paper can achieve a 95% correct rate of activity recognition. We also created a simulated ur5 robotic arm grasping system to reproduce the inferred activity sequence.