Systems

Welding Robot Digital Twin

A live 3D monitoring system that synchronizes physical welding robot joint data with a virtual Unreal Engine counterpart using IoT protocols, enabling remote supervision and anomaly detection.

RoboticsDigital TwinIoT / MQTTKinematicsReal-time Data

Video showing synchronized movements between the physical robot and the digital twin

Bridging the gap between the physical shop floor and digital monitoring, this project established a real-time data pipeline for an industrial welding robot. By subscribing to live sensor data via MQTT, the UE5 application mirrors the robot's kinematic movements and visualizes critical welding parameters such as temperature and voltage directly in 3D space.

Rigged and implemented forward and inverse kinematics for a 6-axis robotic arm in UE5.
Established a low-latency IoT connection using MQTT to stream real-world joint-angle data.
Developed a dynamic UI overlay for real-time hardware telemetry and monitoring.

Designed the skeletal mesh rigging and Control Rig setup for the robot.
Built the Unreal logic to parse incoming telemetry data and map it to robot motion.
Developed the data-visualization UI and warning logic for live parameter thresholds.

Rigging: Prepared the robot CAD model with accurate pivot points and joint hierarchies.
Communication Layer: Set up a local MQTT broker and built the Unreal-side client logic to parse incoming data streams.
Motion Mapping: Mapped received joint-angle values to the virtual robot through animation and rig logic.
Interface Layer: Designed floating UI elements to display welding status and live machine parameters.

Created a scalable template for bringing live heavy machinery into Unreal Engine.
Provided engineers with a safer remote 3D interface for observing hazardous welding operations.