A Digital Twin-Based Framework for Biomechanical Ergonomics Assessment in Human–Robot Collaboration

In today’s manufacturing industry, work-related musculoskeletal disorders (WMSDs) remain among the most prevalent occupational health issues. Collaborative robots (cobots) represent a promising technology to address this challenge. Consequently, ergonomics assessment in human–robot collaboration (HRC) has gained increasing attention in recent years. This study investigates the feasibility of using a coupled digital twin system consisting of a digital human model (DHM) and a cobot digital twin to assess detailed ergonomic parameters such as muscle activations and joint reaction forces in an HRC task. Selected parameters are used to develop an ergonomics map that condenses the effects of human–robot interaction into a single scalar value for each working position in the coronal plane in front of the user. The ergonomics mapping approach is presented, key influencing factors are identified, and critical workspace design implications are discussed.