Collision Avoidance with Deep Learning in a Digital Twin for Industrial Collaborative Robot Manipulation

Safe human–robot collaboration remains a critical challenge in manufacturing. Traditional safety approaches, such as cages and proximity sensors, are often insufficient for dynamic human interaction. This paper presents a digital twin-based collision avoidance framework for industrial collaborative robot manipulation. The system integrates RGB-D sensing, human pose estimation using Ultralytics YOLO26s-pose, Kalman-filter-based 3D arm tracking, short-term motion prediction, and QP-based reactive motion control. Human arm keypoints detected from RGB-D images are reconstructed in 3D, transformed into the robot base frame, and tracked during temporary occlusion using Kalman filtering with kinematic constraints. Predicted human–robot clearance is evaluated to trigger speed reduction, stopping, or collision avoidance commands. The framework was implemented with a UR10e robot, an Intel RealSense D435 camera, a Unity3D digital twin, and ROS communication. Controlled laboratory experiments demonstrated the proof-of-concept feasibility of the integrated framework for tracking human arm motion, anticipating proximity risk, and triggering protective robot responses. The results do not establish deployment readiness in complex industrial or multi-participant environments.