Development and Laboratory Feasibility Validation of a Virtual Reality Simulation Model for Robotic End-Effector Assembly Training

Virtual reality can support the preparation and rehearsal of assembly tasks by providing a safe and repeatable digital representation of workstations. This study presents the development and laboratory feasibility validation of a geometry- and procedure-oriented VR simulation model for the assembly and disassembly of end-effectors on an industrial robot. The workflow was implemented using the Almega AX-V6 robotic workstation as a case study and included geometric acquisition of the real robot, CAD modelling in SolidWorks, redesign of the original end-effector connection using a quick-change flange concept, creation of two alternative end-effector models, modelling of the laboratory workspace in SketchUp, and scene enhancement in Twinmotion. The resulting robot and environment models were integrated in Pixyz Review and deployed through an Oculus Rift-based VR setup. Compared with the original flange concept, which required twelve screws, the redesigned training concept used two screws and two nuts, reducing the number of fastening elements by 66.7% and the number of screw positions by 83.3%. The VR implementation supported visual inspection, controller-based placement and alignment, and symbolic confirmation of fastening steps; it did not include force feedback, threaded fastening physics, automatic error scoring, or quantified transfer-of-training evaluation. Laboratory feasibility validation confirmed correct asset integration, spatial correspondence with the physical workplace, and functional executability of the target exchange sequence. The results show that the workflow is useful as a case-study pipeline for CAD-to-VR modelling and assembly rehearsal, while controlled user studies are still required before claims about training effectiveness can be made.