Robot Simulation
A 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: [Link]
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: [Link]
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 Robot Path Deviation
Error Messages
Source: [Link]
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
Source: [Link]
Where Do I Start?
Balance These Robot Parameters: Balance
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?
Payload Speed
Robot Simulation Can Answer
Questions To Help Balance Robot Reach
Selection
Case Study Machine Tending Workcell
SHAVER
OUTFEED
CHAMFER
INFEED
INSPECT
HOB
LATHE
PART
MARK
Machine Tending Workcell Robot Work Envelope
Design With 3D Model
Difficult To Position
Robot With CAD Software
Robot Simulation
Installed System
In / Out Conveyors Lathe Part Marker
Installed System
Hob Chamfer Shaver
How Do I Do It?
Layout Investigation Program Generation Verification
Library
Layout Programming Simulation
Robot
2D layout import CAD-to-Path Cycle time
Layout creation Graphic jogging Robot trajectory Load program
Easy teaching
to actual robot
Others
Virtual TP
Simple Modeling
3D CAD data
2D-3D conversion Teach robot data
Parts modeling by same operation
IGES Library registration of actual robot
format
CAD Interface
Source: FANUC Robotics
Duty Estimation
Set payload (EOAT and Conditions (Ambient
Work-pieces weight, center temperature, cover option)
of gravity, inertia)
TP OVC, OH
Program Result
Simulation
Source: FANUC Robotics
Life Estimation
Actual cycle time
Working hours per day
Working days per year
Torque analysis
Simulation
Reducers life
TP
Program
Source: FANUC Robotics
Power Estimation
one cycle Power consumption Motion analysis
Simulation
TP
Program Annual power and electric toll
Source: FANUC Robotics
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
Footprint Optimization
Sequence of Operation
Case Study Packing Workcell
Simulation Allowed For
Combined Operations
Reduced From Two
Robots To One Robot
Robot Reach
Footprint Optimization
Sequence of Operation
Deep Containers
Required Attention To
Moment Loading
Custom Simulation Package For Spot Welding
Critical space
3 2 1 3 2 Robot Robot
3D CAD 1
model
1234
4 321
Robot #2
Robot #1
Servo gun posture Assign points to each Compute the
normal to surface robot group and sort critical space and
the order of assigned setup the interlock
points to minimize the signals
path distance
Source: FANUC Robotics
Case Study Spot Welding
Robot Interference
Cycle Time
Workcell Footprint
Sequence of Operation
Source: Octopuz
Case Study Spot / Arc Welding Workcell
Tooling Clearance
Robot Clearance
Cycle Time
Workcell Footprint
Sequence of Operation
Source: Octopuz
Custom Simulation Package For Arc Welding
Work angle Push angle
Welding line
Linear Circular
motion motion
Approach Retreat
point point Avoid Collisions
Source: FANUC Robotics
Case Study Arc Welding
Coordinate Reach With
Positioner
Verify Ability To Reach
All Weld Points
Check Weld Position at
Each Seam
Cycle Time
Source: FANUC Robotics
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
Source: FANUC Robotics
Custom Simulation Package For Palletizing
1. Specify the dimensions of the
work and the palletizing
pattern
Conveyor3
Work Dimensions
Conveyor2
2. Specify the transportation relationship between
Conveyor1 each conveyor and each pallet
3. Specify the work required on each conveyor
Pallet-Station3
Pallet-Station2
4. Generate palletizing Teach Pendant programs
Pallet-Station1
Source: FANUC Robotics
Case Study - Palletizing
Multi-Function EOAT
Slipsheets
Bags
Equipment Location
Footprint Optimization
Sequence of Operation
Source: FANUC Robotics
Case Study - Palletizing
Multi-Function EOAT
Pallet
Pails
Cases (2 Orientations)
Equipment Location
Footprint Optimization
Sequence of Operation
Case Study High Speed Picking
1. Parallel flow
(Life is good at steady state.)
Source: FANUC Robotics
Case Study High Speed Picking
2. Infeed speed/density
(Slower & denser is better.)
Source: FANUC Robotics
Case Study High Speed Picking
3. Boundaries settings
(When theyre good, theyre
good. When theyre bad.)
Source: FANUC Robotics
Case Study High Speed Picking
4. Variable flow
(This is the real world.)
Source: FANUC Robotics
Case Study High Speed Picking
5. Conveyor Stop
(Control your destiny.)
Source: FANUC Robotics
Case Study High Speed Picking
6. De-coupling
(Do it if you can.)
Source: FANUC Robotics
Case Study High Speed Picking
7. Counter Flow
(Its not the silver bullet.)
Source: FANUC Robotics
Case Study High Speed Picking
Robot Position
Conveyor Height and
Position
Conveyor Speed
Number of Robots
Required to Maintain
Production Rate
Custom Simulation Package For Material Removal
Library
CAD Data
Definition of a workcell Placement of the devices models Selection of a chamfering line
Rotate Tooling to
avoid collision
Generate Program with Simulation
Specify Tool Rotation
Collision Avoidance
Source: FANUC Robotics
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 Workcell
Set Up.
Perform What If Analysis of Installed Robotic Systems With No
Down Time.
Use of Simulation When Things Go Wrong
Manual Load/Unload Spot Welder Operation
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: [Link]
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 Doesnt Crash The Robot!
Contact Information
Charles C. Gales, P.E.
Manager, Automation Sales
Weldon Solutions
425 East Berlin Road
York, PA 17608
USA
Telephone: 717-846-4000
Email: cgales@[Link]
[Link]
