Evaluating Cognitive Workload in Industrial Tasks via Immersive VR and Human Digital Twin Frameworks: Development of Application and Design of Experiment

The emergence of Industry 4.0 and 5.0 is reshaping the manufacturing landscape, including human-centric approaches that harmonize human intelligence with machine efficiency. In this context, evaluating cognitive workload is essential to ensure operator well-being and optimize productivity. The Human Digital Twin (HDT) framework presents a promising solution, enabling the virtual simulation of human behavior within industrial environments. When integrated with Immersive Virtual Reality (IVR) and physiological monitoring technologies, HDTs can support the ergonomic and cognitive optimization of workstation design. This paper presents the development of a custom IVR application designed to analyze how different cognitive support conditions impact user performance and psychophysiological responses during simulated industrial assembly tasks. The system incorporates multi-modal data collection, including task performance metrics, eye-tracking data, ECG, and electrodermal activity, complemented by validated subjective questionnaires. The experimental protocol is designed to compare traditional instruction-based interfaces with visually guided support systems within a highly immersive environment.