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ASSIGNMENT 6.1 Exploring the Future of Industrial Robotics: Digital Twin in the Context of Industry 4.0 and 5.0 Christopher Bolt [500843687] Max van Oostveen [500882741] Nour Jamal [500910087] Niels Duineveld Zayed Nurmohamed[500910268] 15-12-2025.

ASSIGNMENT_6.1 Literature and Technology review: Digital Twin What is a Digital Twin: A Digital Twin is a precise, virtual replica of a physical object or process that is connected to reality in real-time through sensors. Since data is constantly exchanged, the digital model behaves exactly like the real system. Industry 4.0 • Focusses on Efficiency, Automation, and IoT. The twin simulates the machine. • It can be used for Predictive Maintenance optimizing production speed, and reducing costs. • Maximize the machine's output. Industry 5.0 • Focusses on Men's central, Sustainability, and Resilience. • Human Centerd. The twin now also incorporates the person and the environment into the model • It can be used for adaptive collaboration, safety and ergonomics, energy savings. • Support the person and protect the environment..

ASSIGNMENT_6.1 Literature and Technology review: Tools Industry 4.0 Simulation & Offline Programming • Examples: ABB, RobotStudio,Siemens Tecnomatix. • Goal: To program robots and simulate collisions without halting production. IoT & Data Platforms • Examples: PTC ThingWorx, Siemens MindSphere. • Goal: To gather data from machines for Predictive Maintenance. PLM (Product Lifecycle Management) • Examples: Dassault 3DExperience, Teamcenter. • Goal: To manage all data related to a product, from design to production. Industry 5.0 Digital Human Modeling (DHM) • Examples: Siemens Jack, Dassault DELMIA Human, RAMSIS. • Goal: To simulate the worker themselves. Can they fit in? Is the posture ergonomic? Do they get tired too quickly? Wearable Integration & AI • Examples: Python, ThingWorx (Human Data). • Goal: To process biological data from smartwatches and translate this into signals for the robot. Immersive Technologies (XR) • Examples: Unity, Unreal Engine, Microsoft HoloLens. • Goal: Training in VR and work instructions via AR to reduce the cognitive load on the worker..

ASSIGNMENT_6.1 Case Study: Twin in Manufacturing Process Planning ☆ Problem: In a factory, there are often different ways to produce the same product.(1th. 3D printing, 2th. welding, 3th. CNC......) ☆-> Witch production option is the best? (6th or 7th) Companies must consider: • Production time • Costs • Energy consumption • Worker safety and workload Normally, this decision is made before production starts, without real-time information. This makes the system inflexible..

ASSIGNMENT_6.1 Case Study: Twin in Manufacturing Process Planning ☆ What is the role off the digital twin? In this case study, a Digital Twin of the manufacturing process is created. This Digital Twin is a digital copy off: • Machines • The production steps • The human worker The Digital Twin receives real-time DATA from the real factory, such as machine status and worker conditions. This allows the system to analyze and simulate the process while production is running. ☆ What does the digital twin measure? • Production time • Production cost • Energy consumption • Environmental impact • Physical workload and fatigue of the worker These KPIs are used to compare different production options..

ASSIGNMENT_6.1 Case Study: Twin in Manufacturing Process Planning ☆ Industry 4.0 and 5.0 The key difference with Industry 4.0 is that human factors are included. In this case study, the Digital Twin does not only focus on machines, but also on: o Worker fatigue o Ergonomics o Safety o Human well-being This makes the system human-centered, which is a core idea of Industry 5.0. ☆ How does the system make decisions? The Digital Twin system: 1- Compares different manufacturing options 2- Weighs all KPIs (time, cost, energy, human factors) 3- Selects the best production option for the current situation If conditions change the Digital Twin updates the decision automatically..

ASSIGNMENT_6.1 Case Study: Twin in Manufacturing Process Planning ☆ Results • Lower energy consumption • Faster production times • Better working conditions for employees • Higher flexibility in production • Increased profit for the company An important conclusion is that: Including human well-being and sustainability improves overall performance instead of reducing it. ☆ Conclusion SHOWs: ➢ How digital twin works. ➢ How it helps with going from industry 4.0 to 5.0. (Humans). ➢ How human-centered decisions can be intergrated into industrial robotics..

ASSIGNMENT_6.1 Debate Arguments Proponents (Arguments for Digital Twin) • Improves efficiency and productivity • Enables real-time monitoring and predictive maintenance • Supports human-robot collaboration (Industry 5.0) • Increases sustainability by reducing energy and waste • Helps companies become more resilient to disruptions Critics (Arguments against Digital Twin) • High complexity of software integration • Cybersecurity and data privacy risks • High implementation and maintenance costs • Lack of standards and interoperability • Need for new skills and worker training.

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