Advanced virtual prototyping of robotic cells using physics-based simulation

This research project develops and tests advanced virtual prototyping methods for robotic manufacturing cells using physics‑based simulation environments. Traditional virtual commissioning often relies on kinematic models that ignore dynamic physical interactions, which creates gaps between simulated and real‑world behavior. To fix this, the study adds multi‑body dynamics, contact mechanics, and sensor feedback into a single virtual prototyping framework. By including realistic constraints such as gravity, friction, inertia, and collision dynamics, the simulation can accurately validate robot trajectories, material‑handling actions, and collaborative tasks. The approach gives step‑by‑step guidance for modeling complex robot assemblies, defining joint types, and configuring physics engines to match measured performance. It also supports analysis of cycle times,

detection of possible collisions, and optimization of control algorithms before hardware is built. This work helps cut commissioning time, reduce equipment wear, and improve safety in automated manufacturing systems. The framework provides a solid tool for virtual verification, offering a systematic way to bridge the gap between digital design and physical implementation of robotic cells.

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