A Digital Twin application for an assembly/disassembly flexible robotic cell assisted by ABB IRB 120 robotic manipulator generating the optimal trajectory for the smallest errors using RobotStudio

This paper presents the development of a Digital Twin (DT) application for a flexible robotic cell (FRC) designed for assembly and disassembly (A/D) tasks, utilizing an ABB industrial robotic manipulator (RM). A 3D simulation environment was built using Siemens NX Mechatronics Concept Designer (MCD). The control of both the physical cell and its virtual counterpart was achieved through a Siemens S7-1200 PLC, programmed in TIA Portal, with the virtual model relying on inverse kinematics algorithms. The concept of Virtual Commissioning (VC) was applied to enhance system performance by enabling task optimization and comprehensive monitoring, analysis, and tracking of manufacturing processes. All robotic trajectories were validated through simulations in RobotStudio. Additionally, the system integrates IoT functionalities and allows remote access via a VPN, enabling remote operation of the 6-DoF ABB IRB 120 robot in the assembly/disassembly robotic cell (A/DRC). The experimental simulations in RobotStudio ensured that the resulting robot paths were optimized for minimal error.