Completion of an Autonomous Sorting Digital Twin System

I have an advanced, near-complete digital twin of an autonomous sorting system that requires an experienced Automation/Mechatronics engineer to bring it to commissioning readiness. The integration framework connecting the KUKA KR 180 R3500 ultra robot, multi-stage conveyor network, and proximity sensing infrastructure is already operational. Core functions, including robot kinematics, I/O communication, and preliminary motion routines, have been successfully validated within the simulation environment. The remaining work focuses on optimization and final system refinement. This includes enhancing PLC control logic and robot motion sequences to improve throughput and reduce cycle times, integrating several additional field devices—including new sensors and a diverter gate—into both the physical control system and the digital twin, and fine-tuning sensor feedback, conveyor synchronization, and robot trajectory planning. The objective is to achieve millimeter-level alignment between the virtual model and the real-world production line. The project utilizes TIA Portal V16 for PLC and drive control and Unity 3D for the digital twin environment. Success will be measured by achieving less than 2% cycle-time variance between the physical and virtual systems during a two-hour stress test, ensuring uninterrupted live OPC UA data exchange for all newly integrated devices, and validating collision-free robot TCP movement within the updated path envelope across both environments. Full project documentation, source files, and remote access to the PLC and robot controller will be provided, along with rapid feedback throughout the implementation process.