AutomationML-Based Digital Twin for a Holistic Data Exchange Between Virtual and Physical Robotic Cells

Robot-based manufacturing cells exhibit strong capability in performing high customizable working cycles involving operations like machining, assembly, painting, welding and gluing. Designing and optimizing such systems require a holistic approach across domains like device layout, logical connections, control systems, and tasks. The AutomationML file format (AML) within the Reference Architectural Model Industrie (RAMI 4.0) framework enhances interconnection and interoperability among engineering tools but lacks established practices. This paper introduces AML for representing flexible manufacturing cells within the Product-Process-Resource paradigm. AML serves as a comprehensive representation of equipment, processed products, and manufacturing operations, aiding design, configuration, virtual simulation, and optimization before physical implementation. A software tool for robotic systems simulation and programming, i.e. RoboDK, is employed to generate customizable virtual prototypes based on AML content for streamlined simulation and assessment. The same AML file facilitates code transfer to physical cell control units. Demonstrated on a robotic deburring cell, this approach highlights AML’s efficacy in data representation between virtual and physical environments, paving the way for digital twin mapping and enhanced manufacturing integration.