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IEEE Access
Article . 2025 . Peer-reviewed
License: CC BY
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IEEE Access
Article . 2025
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Real-Time Digital-Twin-Based Cobot-Worker Collision Risk Prediction Using Unity, ROS, and UWB

Authors: Woojin Kwon; Jieun Yang; Seunghwa Song; Jun Lee; Hyungjung Kim;

Real-Time Digital-Twin-Based Cobot-Worker Collision Risk Prediction Using Unity, ROS, and UWB

Abstract

The growing use of collaborative robots (cobots) in industrial environments raises concerns about worker safety; flexible and adaptive systems are required to predict and prevent real-time cobot-worker collisions. This study proposes a digital-twin-based, cobot-worker collision risk-prediction system that utilizes the Unity game-development engine, robot operating system (ROS), and ultra-wideband (UWB) communication. The proposed system incorporates three modules: 1) real-time cobot-worker data capture, 2) digital-twin-based dynamic collision-zone management, and 3) collision-risk prediction. The core of the system is a data-driven cobot-worker digital twin that reflects the movements of the cobot and worker using ROS and UWB communication. This dynamic approach addresses the limitations of fixed safety-zone configurations by considering the cobot trajectory and the worker path projection in real time within the digital-twin modules. The system demonstrated low latency in data transmission from ROS to Unity (average 13 ms) and from UWB to Unity (average 140 ms), through implementation and evaluation. It also accurately predicted the minimum distance between the worker and cobot, accounting for varying worker speeds and future prediction times. This research offers a promising solution for enhancing worker safety in collaborative robotic environments by providing a real-time, digital-twin-based collision risk prediction system with dynamic collision zone management.

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Keywords

worker safety, collaborative robot, Electrical engineering. Electronics. Nuclear engineering, Digital twin, collision risk prediction, TK1-9971

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
0
Average
Average
Average
gold