Digital Twin and Virtual Monitoring of a 6-DOF Robotic Manipulator

Abstract

Background: Digital twins (DTs) are a key technology of Industry 4.0 and play a crucial role in the digital transformation of industry. The education of experts for the needs of Industry 4.0 and the emerging 5.0 must align with the requirements of practice. However, the availability of these technologies for educational institutions is problematic due to their complexity and limited resources. Methods: This study develops and implements DT and a virtual monitoring system for a specialised 6-DOF laboratory robotic manipulator. The architecture uses a multi-layered communication via middleware KEPServerEX. AI-assisted “Vibe Coding” supports development of a custom Python control application and integration with multiple APIs. Next, the application of a virtual monitoring system enables tracking of selected metrics via a web interface. Results: Our work provides three primary contributions: (1) consolidation of multiple devices through middleware (KEPServerEX) to link robots and PLCs; (2) accelerated development through AI-assisted “Vibe Coding”; and (3) remote accessibility through a custom web-based monitoring platform. Conclusions: The study demonstrates that a fully functional digital twin, integrated with a virtual monitoring system, can be implemented in a university laboratory environment using a combination of cost-effective technologies.