Digital Twin-controlled Modular and Reconfigurable Manufacturing System for Flexible Human-Machine Collaboration in Assembly

This paper addresses the need for adaptable manufacturing systems in Industry 5.0, focusing on reconfigurability in the context of human-machine systems. Current systems lack automated, flexible reconfiguration capabilities, relying on manual setup and expert intervention, which limits their adaptability and increases downtime in dynamic manufacturing environments. To tackle this, we propose a modular, reconfigurable assembly system (RAS) optimized for rapid reconfiguration and seamless collaboration. The system uses a decentralized architecture with plug-and-produce functionality, supported by a Digital Twin (DT) for real-time monitoring and task management. The DT is employed to synchronize the physical and virtual environments, ensuring real-time monitoring and control. It manages the system’s Configuration and task execution through an asset administration shell (AAS) for skill-based task assignment. ROS2/Python integration simplifies hardware expansion. Results show the system’s ability to adapt quickly to various tasks, with the DT improving task precision and flexibility and the human supporting in complex or precise tasks. The system’s modularity and standard components enhance resilience, making it responsive to market changes and disruptions.