A method of virtual modeling and real-time reconstruction for all elements of flexible human-robot assembly unit

With the continuous development of Industry 4.0 and Industry 5.0, the manufacturing industry has an increasing demand for intelligent, human-robot collaboration and flexible production systems. In order to improve flexibility and accuracy in the production process, human-robot collaboration technology has emerged as a core component of smart manufacturing. Although human-robot collaboration technology has been widely used, its performance is still constrained by the frequency of production switching, the lack of collaboration accuracy, and the untimely response to unexpected situations. In order to solve these problems, this paper proposes an all-element virtual modeling and real-time reconfiguration method for flexible human-robot assembly units. It aims to enhance the efficiency and precision of human-robot collaboration through accurate virtual reality technology, and to realize high-precision simulation and optimization of assembly cells by integrating the perception and modeling of people, robots, tasks, and environmental factors. For efficient data collection, format conversion and integration. Firstly, we use the multivariate heterogeneous data fusion technique to construct a unified data fusion channel. Secondly, we design high-fidelity models suitable for human-robot task environments. The model is “form-substance-consistent” and “form-nature-consistent,” and integrates geometric, physical, behavioral, and operational characteristics to capture the full range of human-robot processes. On this basis, the precise mapping of operational data to real-time interactions of these object models is realized through a real-time data-driven interface. This optimizes the accuracy and efficiency of the collaborative human-robot assembly process. Finally, the real-virtual mapping accuracy is verified under experimental conditions at two levels: data transmission and reception accuracy and real-time real-virtual mapping. Provide a new method and technical support for human-robot assembly.