IoT–Cloud-Based Control of a Mechatronic Production Line Assisted by a Dual Cyber–Physical Robotic System Within Digital Twin, AI and Industry/Education 4.0/5.0 Frameworks

This paper presents a Digital Twin (DT)-based framework for the control, monitoring, and intelligent optimization of an Assembly/Disassembly/Repair Mechatronic Production Line (A/D/R MPL), developed as a laboratory platform aligned with Industry/Education 4.0/5.0 paradigms. The A/D/R MPL is assisted by two complementary cyber–physical robotic systems: an Assembly/Disassembly/Replacement Cyber–Physical Robotic System (A/D/R CPRS), and a Mobile Cyber–Physical Robotic System (MCPRS), enabling both fixed and mobile intelligent operations. The CPRS is equipped with an industrial robotic manipulator (IRM) responsible for A/D/R tasks, while the A/D Mechatronic Line (A/D ML) consists of seven interconnected workstations (WS1–WS7) dedicated to storage, transport, quality control, and final product handling. MCPRS includes a wheeled mobile robot (WMR), carrying a robotic manipulator (RM) and Mobile Visual Servoing System (MVSS). Each workstation is connected to a local slave programmable logic controller (PLC), which communicates via PROFIBUS with a master PLC located at the CPRS level. Additional communication infrastructures include LAN PROFINET and LAN Ethernet for local integration, and WAN Ethernet connectivity enabled through open platform Communication-Unified Architecture (OPC-UA), ensuring interoperability, scalability, and remote accessibility. Also, MODBUS TCP as serial industrial communication is used between the master PLC and the MCPRS. Virtual environment supports task planning through Augmented Reality (AR) and real-time monitoring through Virtual Reality (VR). The system behaviour is modelled with synchronized hybrid Petri Nets (SHPNs) which describe the discrete and hybrid dynamics of A/D/R processes. Artificial intelligence (AI) techniques are integrated into the DT framework for optimal task scheduling and adaptive decision-making. As a laboratory-scale implementation, the proposed system provides a comprehensive platform for experimentation, validation, and education. It supports Education 4.0/5.0 objectives by facilitating hands-on learning, human–machine interaction, and the integration of emerging technologies such as AI, Digital Twins, AR/VR, and cyber–physical systems. At the same time, it embodies Industry 4.0/5.0 principles, including interoperability, decentralization, sustainability, robustness, and human-centric design.