Application of Digital Twins in Designing Safety Systems for Robotic Stations

The aim of this paper is to present examples and original solutions related to the application of the digital twin concept in designing safety systems for robotic stations. This paper includes a review of publications on robot safety systems and digital twins. Based on this review, it was concluded that further work in this area is justified. This paper demonstrates the use of a digital model of a robotic casting mold preparation station to design safety components for an industrial cell. A key element of this paper is the presentation of developed algorithms and their applications in building digital twins of existing robotic stations. By characterizing advanced safety systems used in robotic stations, an example of using a digital twin of a robotic station to create safety zones and so-called restricted zones for the robot was developed. As part of the research conducted, a real, comprehensive example of creating safety zones based on the robot’s TCP paths was carried out.