Autonomous Sorting Digital Twin Finalization- -- 5

I have a nearly finished, high-fidelity digital twin of an autonomous sorting line that still needs a senior Automation / Mechatronics touch before it can be signed off for commissioning. The core bridge between the KUKA KR 180 R3500 ultra, our multi-stage conveyors and all proximity sensors is already built and running; kinematics, basic I/O mapping and initial motion programs are proven in simulation.

What remains is the polish and performance work:

• Optimise the existing PLC-level logic and motion sequences for smoother throughput and cycle-time reduction.
• Integrate a handful of new field devices (additional sensors and a diverter gate) into both the real PLC and the twin.
• Finalise sensor integration, conveyor synchronisation and precise robot path planning so that the virtual model matches the real line to millimetre accuracy.

Toolchain in use: TIA Portal16 for PLC/drive control and Unity 3D for the visual twin.

Acceptance criteria
1. Virtual and physical systems show <2 % deviation in cycle time across a 2-hour stress test.
2. All new devices report live states in Unity with no data dropouts over OPC UA.
3. Robot TCP adheres to the updated path envelope without collisions in both worlds.

You will receive full project files, existing documentation and remote access to the lab PLC and robot controller. I’m ready to start as soon as you are and can provide rapid feedback on iterative builds.