Location-Independent Robot-Assisted Finishing Using Digital Twins and Extended Reality

Abstract

This paper presents a cyber-physical system (CPS) for location-independent programming, supervision, training, and teleoperation of a Robot-Assisted Finishing (RAF) system used to post-process metal additive-manufactured (AM) components. A digital twin (DT) built in Unity is delivered to the operator as a WebGL application that supports both desktop and immersive modes through WebXR-compatible devices. Moreover, it exchanges robot state and pose commands with a collaborative robot through a Message Queuing Telemetry Transport (MQTT) broker. The DT enforces kinematic and collision constraints before a pose is released to the physical robot, and augments the virtual component with a color map of the surface topography that supports operator decisions on part repositioning or process termination. The architecture was validated on a specially designed physical RAF system. A steady-state joint synchronization error of 0.12 deg and a mean round-trip latency of 563 ms were measured, which is adequate for supervisory programming and intermittent teleoperation.