A Digital Twin Framework for Real-Time Analysis and Feedback of Repetitive Work in the Manual Material Handling Industry

This research presents a digital twin concept and prototype to represent human operators in the material handling industry. To construct the digital twin, we use a simulation-based framework for data collection and analysis. The framework consists of three modules: Data Collection Module, Operator Analysis and Feedback Module and Digital Twin Module. A motion capture system assists in the development of the digital twin, which captures simulated material handling activities, similar to those which take place in an actual environment. This paper outlines the processes involved in the development of the digital twin and summarizes the results of pilot experiments to analyze the operator's fatigue as the operator completes repetitive motions associated with lifting tasks. Fatigue, in this study, is a function of change in joint angles. The digital-twin based tool provides feedback to the operator in real-time to enable correction of those factors which potentially cause injuries to the operator.