Applied Sciences, Vol. 13, Pages 4229: Applying Digital Twin and Multi-Adaptive Genetic Algorithms in Human–Robot Cooperative Assembly Optimization

Applied Sciences, Vol. 13, Pages 4229: Applying Digital Twin and Multi-Adaptive Genetic Algorithms in Human–Robot Cooperative Assembly Optimization

Applied Sciences doi: 10.3390/app13074229

Authors: Doan Thanh Xuan Tran Van Huynh Nguyen Thanh Hung Vu Toan Thang

In this study, we utilized digital twin technology in combination with genetic algorithms to optimize human–robot cooperation in a miniature light bulb assembly production line. First, the digital twin was used to find the robot’s motion trajectory; a digital replica of the assembly system and human was created by combining sensors that track the position and activity characteristics of the human in the workspace, which helped to prevent human–robot conflicts. Then, a multi-adaptive genetic algorithm was applied to calculate optimal ergonomics and create a worker’s movement schedule. To ensure continuous operation and no shortage of materials, the worker must observe and move to the input conveyor and material pallets to supply materials to the system. It aimed to provide more input materials for the assembly line while allowing the worker’s task to take place in parallel with the robotic assembly operation. The algorithm was designed to reduce the number of moves required to obtain materials and to ensure that the robot always had enough materials to assemble along the defined trajectory, thus, saving labor and optimizing the manufacturing process. The combination of a digital twin and multi-adaptive genetic algorithm optimized the robot’s movement path and the number of movements performed by the human operator in parallel.