Digital-Twin based development of Remote Handling facilities for fusion reactors from design to operation

Remote Handling (RH) systems are vital for maintaining highly activated fusion reactor components, and need extensive testing, validation and commissioning in dedicated RH facilities before starting operate, The thesis tackles the full-cycle development of Remote Handling (RH) facilities by proposing a digital-twin, model-driven workflow that spans concept to operations. Building on Industry 4.0 and Model-Based Systems Engineering (MBSE) frameworks, such as the V-model with RFLP, it uses a PLM platform (3DEXPERIENCE) to unify requirements, 3D CAD, robotics simulation, maintenance planning, and traceability, enabling faster, safer, and more cost-effective RH development. The approach is demonstrated on the DTT RH Facility, one of the first testbeds to integrate nearly all RH subsystems, where simulations support both design verification and operator training and remain synchronized with evolving CAD models. A key contribution is a digital-physical calibration method, developed through the Structural Simulator within ITER’s RH Control System Virtual Reality module, that introduces virtual joints driven by on-site measurements to mirror real structural behavior, improving trajectory accuracy and operator confidence. The workflow is transferable to other fusion projects, with future enhancements aimed at tighter digital twin to control system coupling, data governance, Machine Learning-assisted calibration, calibration prediction through Finite Element and tolerance analyses, and digital-physical deviation compensation. Overall, the work provides a scalable roadmap for RH facilities that elevates reliability, maintainability, and operational readiness in fusion.