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Abstract <p>This paper addresses the critical requirement for high-fidelity Digital Twin (DT) by presenting a detailed methodology for the design, development, and validation of a comprehensive DT for the Yaskawa GP4 6-DOF industrial manipulator. The core technical challenge is achieving ultra-low latency, closed-loop synchronization between the physical and virtual domains. Our novel approach leverages the proprietary YMConnect Application Programming Interface (API) to establish a dedicated, high-speed, bidirectional communication channel over industrial Ethernet, effectively bypassing conventional fieldbus layers to directly access the internal kinematic and control variables of the robot controller. This architecture allows the DT environment, built upon a precise kinematic model, to ingest the physical robot’s complete kinematic state vector, including joint positions, velocities, and accelerations, at a synchronous, high-frequency rate, ensuring millisecond synchronization. While this foundational work focuses primarily on high-fidelity kinematic mirroring and control, the established low-latency communication pathway is explicitly designed to support future integration of the robot’s dynamic model by transmitting variables like drive torque feedback. We detail the implementation of remote control, with empirical validation demonstrating reliable command execution and state update cycles achieved in under 20 milliseconds. The findings validate a robust, API-centric architecture that significantly contributes to the field of real-time industrial automation and advanced control systems by providing a scalable blueprint for highly responsive, kinematically accurate DT, thereby advancing operational efficiency, virtual commissioning, and motion planning capabilities of smart factories.</p> Graphic Abstract <p><b>High-Fidelity Digital Twins Implementation for the Yaskawa GP4 Robot via YMConnect and High-Speed Ethernet Communication.</b> This study presents a high-fidelity Digital Twin (DT) framework for the Yaskawa GP4 6-DOF industrial manipulator, enabling near real-time, bidirectional synchronization between physical and virtual domains. The architecture leverages the proprietary YMConnect API over high-speed Ethernet to establish a dedicated communication channel with direct access to controller-level kinematic variables. By bypassing conventional fieldbus layers, the proposed approach achieves low-latency data exchange and deterministic state acquisition. The DT continuously mirrors the complete kinematic state vector, including joint positions, velocities, and accelerations, while supporting remote trajectory execution. Experimental validation in an industrial glue-dispensing task demonstrates sub-millimeter positional fidelity and average end-to-end latency of approximately 21 ms, confirming suitability for virtual commissioning and smart manufacturing applications.</p>

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High-fidelity digital twin implementation for the yaskawa GP4 robot via YMConnect and high-speed ethernet communication

  • 期刊论文

  • 发表日期：

    2026年5月30日

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  • Gia Loc Pham,
  • The-Mong Bui,
  • Hoang-Viet Dang,
  • Dang Minh Tran,
  • Danh Huy Nguyen

摘要

Abstract

This paper addresses the critical requirement for high-fidelity Digital Twin (DT) by presenting a detailed methodology for the design, development, and validation of a comprehensive DT for the Yaskawa GP4 6-DOF industrial manipulator. The core technical challenge is achieving ultra-low latency, closed-loop synchronization between the physical and virtual domains. Our novel approach leverages the proprietary YMConnect Application Programming Interface (API) to establish a dedicated, high-speed, bidirectional communication channel over industrial Ethernet, effectively bypassing conventional fieldbus layers to directly access the internal kinematic and control variables of the robot controller. This architecture allows the DT environment, built upon a precise kinematic model, to ingest the physical robot’s complete kinematic state vector, including joint positions, velocities, and accelerations, at a synchronous, high-frequency rate, ensuring millisecond synchronization. While this foundational work focuses primarily on high-fidelity kinematic mirroring and control, the established low-latency communication pathway is explicitly designed to support future integration of the robot’s dynamic model by transmitting variables like drive torque feedback. We detail the implementation of remote control, with empirical validation demonstrating reliable command execution and state update cycles achieved in under 20 milliseconds. The findings validate a robust, API-centric architecture that significantly contributes to the field of real-time industrial automation and advanced control systems by providing a scalable blueprint for highly responsive, kinematically accurate DT, thereby advancing operational efficiency, virtual commissioning, and motion planning capabilities of smart factories.

Graphic Abstract

High-Fidelity Digital Twins Implementation for the Yaskawa GP4 Robot via YMConnect and High-Speed Ethernet Communication. This study presents a high-fidelity Digital Twin (DT) framework for the Yaskawa GP4 6-DOF industrial manipulator, enabling near real-time, bidirectional synchronization between physical and virtual domains. The architecture leverages the proprietary YMConnect API over high-speed Ethernet to establish a dedicated communication channel with direct access to controller-level kinematic variables. By bypassing conventional fieldbus layers, the proposed approach achieves low-latency data exchange and deterministic state acquisition. The DT continuously mirrors the complete kinematic state vector, including joint positions, velocities, and accelerations, while supporting remote trajectory execution. Experimental validation in an industrial glue-dispensing task demonstrates sub-millimeter positional fidelity and average end-to-end latency of approximately 21 ms, confirming suitability for virtual commissioning and smart manufacturing applications.