Virtual

Virtual process design with digital twins - using the example of a robot system

How can modern robot systems be simulated, monitored and optimized in real time? We answered this question at our information event on October 2, 2025 - using an innovative application for virtual process design with digital twins. The focus was on a digital twin process simulation using the example of a Stäubli robot cell with a connection to the NVIDIA Omniverse, implemented in cooperation with ARENA2036, ISG, ISW and Collectu.

The slides of the event are available here:
Presentation slides of the Deep Dive "Virtual process design with digital twins".

Asset connectivity with Stäubli robots

The ISG's Stäubli robot system was operated via a Beckhoff controller and digitally simulated using the ISG-virtuos simulation software. The special feature: the real robot cell communicated continuously with its digital image - the so-called digital twin. This connection enables virtual process design in real time, which significantly outperforms conventional simulation methods. The physical system was connected via Beckhoff Industrial PCs with TwinCAT control software. The recorded process data is fed into the Collectu.de platform via a connectivity solution. There they can be read out, structured and made accessible for further applications.

Connection to the NVIDIA Omniverse

The integration into the NVIDIA Omniverse platform represents particular added value in terms of cross-company collaboration scenarios. A specially developed data connector creates a digital twin of the robot system - fed with live data. In this way, the real system is virtually mapped in an interactive 3D environment. In this environment, maintenance scenarios, collisions or process optimizations can be realistically tested - all without interfering with ongoing operations.