charles c. gales, p.e. manager, automation sales … working hours per day working days per year ......

Robot SimulationA Tool For Project Success

Charles C. Gales, P.E.Manager, Automation Sales

Weldon Solutions

Definition

sim - u - la - tion

The activity of producing conditions which are similar to real ones, especially in order to test something, or

the conditions that are produced.

Source: ldoceonline.com

Robot Simulation – Historical Perspective

• Early 1990s, High End Work Stations produced marginal results.

• Robot Models (RobCad, Delmia, Process Simulate) were not precise.

• Each simulation software manufacturer emulated Robot motion system and performance.

• Cycle times and Robot paths did not match the real world.

• Required significant rework to match actual system to design requirements.

• Garbage in – Garbage out

Realistic Robot Simulation

• Initiative of:• Automotive Companies

• Robot Manufacturers

• Simulator Manufacturers

• Line Builders

• Measurement System Manufacturers

• For Enhancing• Robot Simulation Accuracy

• Robot Off-Line Programming Methodology

Source: realistic-robot-simulation.org

RRS-1, Robot Controller Simulation (RCS)

• RCS Interface• Original Motion Control Software

Developed as a Call Library

• Call Library Provided For Groups, Such As:

• Interpolation

• Transformation

• Kinematics Cell Modeling

• Machine Data

• External Axes

• Conveyor Synchronization

• Event Generation

• Error Messages

Robot Path Deviation


RRS-2, Virtual Robot Controller (VRC)

• VRC Interface• Near Complete Integration of Robot

Controller Software Into Simulation

• Six Categories of Services• Real Controller Interface

• I/O Communication

• File System Transfer

• User Interface

• Virtual Controller Interface• Base Commands

• Time Management

• Simulator Support

VRC Functional Groups


Where Do I Start?

• Balance These Robot Parameters:• Payload

• Reach

• Speed

• Robots Are Generally Rated By Payload.• If Robot Has Payload Capacity, Will It Have

Enough Reach?

• If Robot Has Payload Capacity, Will It Have Sufficient Speed?

• Robot Simulation Can Answer Questions To Help Balance Robot Selection

Payload

Reach

Balance

Speed

Case Study – Machine Tending Workcell

LATHE

PARTMARK

INFEED

CHAMFER

SHAVER

HOB

OUTFEED

INSPECT

Machine Tending Workcell – Robot Work Envelope

Design With 3D Model

Difficult To Position

Robot With CAD Software

Robot Simulation

Installed System

Part MarkerLatheIn / Out Conveyors

Installed System

Hob Chamfer Shaver

How Do I Do It?

Programming SimulationLayoutLibrary

Robot

Others

Simple Modeling3D CAD data

CAD Interface

IGES

format

Layout Investigation Program Generation Verification

Virtual TP

2D-3D conversion Parts modeling Library registration

2D layout import Layout creation

CAD-to-Path Graphic jogging Easy teaching

Cycle time Robot trajectory

Teach robot data

by same operation

of actual robot

Load program

to actual robot

Source: FANUC Robotics

Duty Estimation

Simulation

TPProgram

OVC, OH

Result

Set payload (EOAT and

Work-piece’s weight, center

of gravity, inertia)

Conditions (Ambient

temperature, cover option)


Life Estimation

TPProgram

Simulation

Actual cycle time

Working hours per day

Working days per year

Reducer’s life

Torque analysis


Power Estimation

TPProgram

Simulation

one cycle Power consumption

Annual power and electric toll

Motion analysis


Case Study – Multi-Robot Workcell

• Cycle Time• Robot 1 – Machine Tending

• Robot 2 – Machine Tending

• Robot 3 – Packing

• Robot Reach

• Footprint Optimization

• Sequence of Operation

• Prevent Robot Interference

Case Study - Assembly

• Cycle Time• Workcell Arrangement

• Combined EOAT Functions

• Robot Reach



Case Study – Packing Workcell

• Simulation Allowed For Combined Operations

• Reduced From Two Robots To One Robot

• Robot Reach



• Deep Containers Required Attention To Moment Loading

Custom Simulation Package For Spot Welding

3D CAD

model

Servo gun posture

normal to surface

Assign points to each

robot group and sort

the order of assigned

points to minimize the

path distance

Compute the

critical space and

setup the interlock

signals

Critical space

Robot #1Robot #2

3 2 1

1 2 3 4

123123 Robot Robot

4


Case Study – Spot Welding

• Robot Interference

• Cycle Time

• Workcell Footprint


Source: Octopuz

Case Study – Spot / Arc Welding Workcell

• Tooling Clearance

• Robot Clearance

• Cycle Time

• Workcell Footprint


Source: Octopuz

Custom Simulation Package For Arc Welding

Circular

motion

Linear

motion

Approach

pointRetreat

point

Welding line

Push angleWork angle

Avoid Collisions


Case Study – Arc Welding

• Coordinate Reach With Positioner

• Verify Ability To Reach All Weld Points

• Check Weld Position at Each Seam

• Cycle Time


Case Study – Arc Welding

• Coordinate Reach With Positioner

• Verify Ability To Reach All Weld Points

• Check Weld Position at Each Seam

• Confirm Operator Safety During Unload / Load

• Cycle Time


Custom Simulation Package For Palletizing

4. Generate palletizing Teach Pendant programs

2. Specify the transportation relationship between

each conveyor and each pallet

3. Specify the work required on each conveyor

Conveyor1

Conveyor2

Conveyor3

Pallet-Station2

Pallet-Station3

Work Dimensions

1. Specify the dimensions of the

work and the palletizing

pattern

Pallet-Station1


Case Study - Palletizing

• Multi-Function EOAT• Slipsheets

• Bags

• Equipment Location




Case Study - Palletizing

• Multi-Function EOAT• Pallet

• Pails

• Cases (2 Orientations)

• Equipment Location



Case Study – High Speed Picking

1. Parallel flow(Life is good at steady state.)



2. Infeed speed/density(Slower & denser is better.)



3. Boundaries settings(When they’re good, they’regood. When they’re bad….)



4. Variable flow(This is the real world.)



5. Conveyor Stop(Control your destiny.)



6. De-coupling(Do it if you can.)



7. Counter Flow(It’s not the silver bullet.)



• Robot Position

• Conveyor Height and Position

• Conveyor Speed

• Number of Robots Required to Maintain Production Rate

Custom Simulation Package For Material Removal

Placement of the device’s models

Library

CAD Data

Selection of a chamfering line

Rotate Tooling to

avoid collision

Specify Tool Rotation Simulation

Definition of a workcell

Generate Program with

Collision Avoidance


Case Study – Material Removal

• Process To Part

• Cycle Time

• CAD-To-Path

• Orientation of Deburr Spindle Relative To Part

Case Study – Material Removal

• Part to Process

• Cycle Time• Need For Two Robots

• Minimize Footprint

• Prevent Robot Interference

Benefits of Robot Simulation Software

• Quickly Test Numerous Options With Simulation Software.

• Qualify Applications Faster And More Accurately Than With Manual Methods.

• Validate Robot Applications Without Acquiring Costly Equipment.

• Validate Robot Applications Without Time Consuming WorkcellSet Up.

• Perform “What If” Analysis of Installed Robotic Systems With No Down Time.

Use of Simulation When Things Go Wrong

Spot Welder OperationManual Load/Unload

Spot Welding - Simulation

Spot Welding - Installation

Simulated 20kg Robot

Selected 50kg Robot

Typical Features of Process Line Simulation Software

• Beyond The VRC (Virtual Robot Controller)• Replicate and test complex mechanical systems.

• Control the simulation using an actual PLC logic simulation.

• Optimize part-handling operations.

• Analyze component usage to easily find bottlenecks before the cell is ever built.

• Visualize the shop floor process from start to finish.

• Setup I/O communication between components.

Source: Octopuz

Process Line Simulation

• Robotic Case Packing

• Case Recirculation

• Tote Box Conveying

• Pallet Feeding

• Gantry Palletizer

Source: Octopuz

Benefits of Process Line Simulation Software

• Reduced Cost of Change With Early Detection of Product and Process Design Issues.

• Reduced Number of Physical Prototypes Through Virtual Validation.

• Optimized Cycle Times Through Simulation.

• Virtual Validation of Both Mechanical and Electrical (PLC and Robotics) System Components and Processes

Source: plm.automation.siemens.com

The Future of Robot Simulation

• More Specialized Application Tools• Spot Welding

• Arc Welding

• Palletizing

• Picking

• Painting

• Material Removal

• Improved CAD-to-Path

• Recent Enhancements• Modeling of Robot Dress-Out

• Safety

• Ergonomic Considerations

Robot Simulation – Summary

• Powerful• More Features Being Developed

• Improved Ease of Use

• Remote Program Editing

• Has Moved Beyond Path and Cycle Time• Payload / Moment Check

• Interference

• Duty Cycle

• Robot Life Cycle Estimate

• Broader Perspective: Look At Entire Process Line

• Cost Effective Tool

Test The System With The Model!

Robot Simulation – Doesn’t Crash The Robot!

Contact Information

Charles C. Gales, P.E.Manager, Automation Sales

Weldon Solutions425 East Berlin Road

York, PA 17608

USA

Telephone: 717-846-4000

Email: [email protected]

www.weldonsolutions.com

charles c. gales, p.e. manager, automation sales … working hours per day working days per year ......

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