A digital twin-based smart assembly for cable-driven parallel robots

doi:10.1016/j.aei.2025.103623

A digital twin-based smart assembly for cable-driven parallel robots

2025-07-07

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DOI：10.1016/j.aei.2025.103623

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With the rapid development of advanced enabling technologies such as cloud computing, large language models, big data, and digital twin (DT), smart assembly has emerged as a central focus within smart manufacturing research. Robots, serving as indispensable execution units in this domain, have traditionally been implemented in serial or rigid parallel configurations. However, these robots typically encounter challenges such as limited load capacity, insufficient rigidity, and complex singularities. Although DT technology has been increasingly applied to robot modeling and simulation, current research falls short in addressing coordinating dynamic assembly processes and ensuring digital-physical synchronization. This gap fails to fully meet the demands of complex assembly tasks. To address these challenges, this study investigates cable-driven parallel robots (CDPRs) with a large workspace, high load capacity, and strong dynamic performance. A DT-based smart assembly application framework for CDPRs is proposed, and four key technologies are explored in depth: (1) cable-driven parallel robots assembly process digital twin (CAPDT) model construction; (2) task-level assembly planning; (3) adaptive assembly instruction generation; and (4) CAPDT model consistency retention. These technologies collectively support assembly task planning, simulation verification, performance control, and process management. Finally, a simplified satellite assembly task is presented as a case study, and a DT-based CDPR assembly prototype system for is developed to validate the effectiveness of the proposed application framework and technologies.

A digital twin-based smart assembly for cable-driven parallel robots

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