Current trend in automation area is focused to the innovation in all fields of the technologies and technological devices. Probably industrial robots and manipulators belong to development too. Industrial robots and manipulators belong to progressive elements of automation. Modern concept uses the offline programming as a tools integration of the virtual CAD models into programming environment. Offline programming carries a lot of advantages for example possibility of the programming without real robot system, possibility of the collision state debugging. Implementation of CAD models in virtual environment of Robot studio achieves better workplace station of creating robotic system and also it generates rather trajectories of the robot path in this system.

Modern manufacturing systems are influenced by the growing complexity of mechatronics, control systems, IIoT, and communication technologies integrated into cyber-physical systems. These systems demand flexibility, modularity, and rapid project execution, making digital tools critical for their design. Virtual commissioning, based on digital twins, enables the testing and validation of control systems and designs in virtual environments, reducing risks and accelerating time-to-market. This research explores the development of digital twin models to bridge the gap between simulation and real-world validation. The models identify design flaws, validate the PLC control code, and ensure interoperability across software platforms. A case study involving a modular Festo manufacturing system modelled in Tecnomatix Process Simulate demonstrates the ability of digital twins to detect inefficiencies, such as collision risks, and to validate automation systems virtually. This study highlights the advantages of virtual commissioning for optimizing manufacturing systems. Communication testing showed compatibility across platforms but revealed limitations with certain data types due to software constraints. This research provides practical insights into creating robust digital twin models, improving the flexibility, efficiency, and quality of manufacturing system design. It also offers recommendations to address current challenges in interoperability and system performance.

Designing of the conveyors and its control system with control program through the design tool "Virtual Commissioning" is very important in the digital era Industry 4.0. Virtual Commissioning was recently used to perform realistic virtual simulations in the early stages of development processes in automation of the conveyors too. The main benefit is the possibility of integrating and testing the control system through the simulation on the virtual model even before physically constructing the conveyor. The contribution focuses on the possibilities of transforming a real conveyor into a virtual model in the Siemens Tecnomatix Process Simulate program and integrating the Siemens S7-300 real control system to control the conveyor itself. In the model it was allowed to test and perform numerous variations and situations without physical intervention into the real conveyor and possible damage functional parts including through virtual reality. These experiments were subsequently evaluated and the control system optimized with respect to material flow and the developed PLC code on virtual model was verified on real conveyor control system.

Optimizing the energy efficiency of robotic workstations is a key aspect of industrial automation. This study focuses on the analysis of the relationship between the position of the robot base and its energy consumption and time aspects. A number of 6-axis robots, including the ABB IRB 120 robot, were investigated in this research by combining measurements and simulations using the energy consumption measurement module in the ABB RobotStudio 2024.1.1 environment. The objective of this study was to develop an energy consumption model that can identify the optimal robot positions to minimize energy costs and time losses. The results suggest that the strategic positioning of the robot has a significant impact on its performance and efficiency. These results demonstrate that the ideal working distance of the robots is approximately 50% of its maximum range, and displacements along the X and Z axes affect the energy and time consumption. These findings suggest the existence of a trade-off between time and energy efficiency, providing a basis for further research into the optimization of robotic systems. Thus, this work offers new perspectives for the design of efficient robotic workstations for cross-sensory applications.

We describe a method for robotic cell optimization by changing the placement of the robot manipulator within the cell in applications with a fixed end-point trajectory. The goal is to reduce the overall robot joint wear and to prevent uneven joint wear when one or several joints are stressed more than the other joints. Joint wear is approximated by calculating the integral of the mechanical work of each joint during the whole trajectory, which depends on the joint angular velocity and torque. The method relies on using a dynamic simulation for the evaluation of the torques and velocities in robot joints for individual robot positions. Verification of the method was performed using CoppeliaSim and a laboratory robotic cell with the collaborative robot UR3. The results confirmed that, with proper robot base placement, the overall wear of the joints of a robotic arm could be reduced from 22% to 53% depending on the trajectory.

Virtual Commissioning (VC) is a method and tool for verifying and testing the PLC control program on a virtual digital model of the manufacturing system. It allows to visualize and test the control system before the real commissioning of the production systems. The aim of the research is to implement virtual reality (VR) into the VC method and to verify the mutual interaction of signals between the simulation in VR environment, the digital model of the production system and the control system. The introduction of VR in VC increases the concept by adding more realistic visualization and tracking, which extends its validation capabilities. The changes made in VR virtual environment are transferred to the simulation model and can be validated in a real production system. The real production robotic system transformed into a virtual form will be a case study with its verification. Also will be tested security protocols and proven human interaction with the system to control the system through the virtual HMI (virtual user interface) using VR.