Mobile robots have an important role in material handling in manufacturing and can be used for a variety of automated tasks. The accuracy of the robot’s moving trajectory has become a key issue affecting its work efficiency. This paper presents a method for optimizing the trajectory of the mobile robot based on the digital twin of the robot. The digital twin of the mobile robot is created by Unity, and the trajectory of the mobile robot is trained in the virtual environment and applied to the physical space. The simulation training in the virtual environment provides schemes for the actual movement of the robot. Based on the actual movement data returned by the physical robot, the preset trajectory of the virtual robot is dynamically adjusted, which in turn enables the correction of the movement trajectory of the physical robot. The contribution of this work is the use of genetic algorithms for path planning of robots, which enables trajectory optimization of mobile robots by reducing the error in the movement trajectory of physical robots through the interaction of virtual and real data. It provides a method to map learning in the virtual domain to the physical robot.

With the manipulator performs fixed-point tasks, it becomes adversely affected by external disturbances, parameter variations, and random noise. Therefore, it is essential to improve the robust and accuracy of the controller. In this article, a self-tuning particle swarm optimization (PSO) fuzzy PID positioning controller is designed based on fuzzy PID control. The quantization and scaling factors in the fuzzy PID algorithm are optimized by PSO in order to achieve high robustness and high accuracy of the manipulator. First of all, a mathematical model of the manipulator is developed, and the manipulator positioning controller is designed. A PD control strategy with compensation for gravity is used for the positioning control system. Then, the PID controller parameters dynamically are minute-tuned by the fuzzy controller 1. Through a closed-loop control loop to adjust the magnitude of the quantization factors–proportionality factors online. Correction values are outputted by the modified fuzzy controller 2. A quantization factor–proportion factor online self-tuning strategy is achieved to find the optimal parameters for the controller. Finally, the control performance of the improved controller is verified by the simulation environment. The results show that the transient response speed, tracking accuracy, and follower characteristics of the system are significantly improved.