Virtual Commissioning System for Ergonomic Robot Safety

The patent creates a virtual copy of the real production environment including a digital twin of the operator with anatomically correct body segments. This virtual operator model replicates human anatomy and movement capabilities, enabling ergonomic evaluation within the virtual commissioning environment while maintaining technical simulation accuracy.

The patent introduces a motion capture system as an intermediary between the real operator and the virtual simulation. The motion capture device records actual operator movements and transfers them to the virtual operator model, enabling realistic ergonomic assessment without requiring direct physical interaction with the actual production equipment.

The patent performs ergonomic evaluations in advance during the virtual commissioning phase. By using the virtual operator model to test different workstation configurations and task sequences before actual production setup, ergonomic issues are identified and resolved beforehand, eliminating the need for time-consuming iterative adjustments on the real production line.

The virtual operator model serves as a surrogate for the real operator, allowing comprehensive ergonomic testing in the virtual environment. This copying approach enables multiple simulation scenarios to be tested rapidly without involving actual operators, significantly reducing commissioning time while maintaining ergonomic assessment validity.