Digital Twin Framework for Robot Path Planning and Real-Time Execution Using Unity-ROS Integration: Systems Architecture and Experimental Validation

Digital Twin (DT) systems combining physics-based simulation with hardware execution are critical for Industry 4.0 manufacturing, yet proprietary software solutions remain expensive and platform-dependent. This work addresses three technical challenges: maintaining geometric and kinematic fidelity across CAD-to-simulation conversion pipelines, synchronizing dual physics engines (Unity and ROS middleware) under hardware latency constraints, and optimizing motion planning while preserving trajectory quality and interactive responsiveness. We developed an integrated framework for a 7‑Degree of Freedom manipulator using CAD modeling, URDF/SRDF semantic representation, and bidirectional Unity-ROS (Robot Operating System) communication via WebSocket connectors. Motion planning uses RRTConnect from OMPL with collision-aware optimization through the Flexible Collision Library. Validation across 12 manipulation trials demonstrated positional synchronization accuracy of ±2.0 degrees, motion planning performance of 0.064 ± 0.020 seconds. Latency analysis reveals that hardware execution to be the dominant system bottleneck, significantly exceeding network communication delays. The system achieves performance metrics comparable to proprietary industrial solutions. This work establishes a replicable, cost-effective Industry 4.0 framework, demonstrating that modern game engine technology combined with open-source robotics middleware can deliver DT systems matching proprietary solutions. The architecture and validated implementation enable adaptation to alternative robotic platforms and support broader adoption of simulation-validated automation in manufacturing contexts.