Application of a digital twin of a robotic welding complex for torch trajectory optimization

Abstract

The study is devoted to the application of digital twin technology to improve the efficiency of robotic welding complexes in modern mechanical engineering. The transition from traditional robot programming by teaching to virtual simulation in CAD/CAE environments is substantiated as a key factor in reducing production downtime and increasing technological flexibility. A method for optimizing the trajectory of the welding torch is proposed based on minimizing the welding cycle time and automatic collision detection during motion simulation. The digital twin model enables accurate reproduction of the robot kinematics, including dynamic constraints such as acceleration and inertial effects. Simulation results demonstrate improved trajectory smoothness and reduced velocity variation, which is essential for ensuring uniform weld quality. The implementation of virtual modeling allows early detection of programming errors and eliminates the risk of equipment damage. The approach significantly reduces setup time and enhances operational safety, confirming the effectiveness of digital twin integration into robotic welding systems.