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Robotic Programming for High-Mix Applications

Chahe BakmazjianFounder and Team LeaderHypertherm Robotic Software

TABLE OF CONTENTS

Drivers for high‐mix low‐batch productionRobot programming barriersTask based programmingSmart factories

INDUSTRY DRIVERS

INDUSTRY DRIVERS

Advances in manufacturing

Global Economy

Flexible Automation

Just-in-Time / Lean

Innovative new processes

▲ Performance, ▼Costs

ROI /Capital expendituresCopyright 2016, Hypertherm, Inc. All rights reserved.

INDUSTRY DRIVERS

New robotic markets emerging

• Milling and trimming• Cutting (laser, plasma,

waterjet)• Welding• Painting, spraying,

dispensing• Polishing, grinding,

sanding

Copyright 2016, Hypertherm, Inc. All rights reserved.

INDUSTRY DRIVERS

New robotic markets emerging

Roadmap to the Future by Paul Kellett , RIA Director - Market Analysis

“The model company is no longer a large entity such as GM, Chrysler, or Ford but small and medium sized enterprises…. The need in such an economy is far more dependent on higher degrees of adaptation, ease of use, and other factors that enable small runs of made-to-order products.”

INDUSTRY DRIVERS

Robots an ideal solution meeting requirements of many industriesEnd-User Segment Process Product

All segments Milling Rapid prototyping

Aerospace Grinding, polishing, drilling, cuttingTurbine blades, bulkheads, insulation, wing

segments

Automotive De-flashing, grinding, drilling, milling, cuttingEngines, truck frames, body panels, door knobs,

bumpers, stamping dies, sand coresFashion Milling, sanding Mannequin molds, mannequins

Foundries De-burring, milling, drilling, routing, finishing Molds, castingsMarine Milling Boat haulsMedical Grinding, polishing Prosthesis

Entertainment Ind. Milling Move set props, amusement park sceneryPlastics Milling, routing Molds, helmets

Woodworking Milling, routingHot-tub molds, furniture, trim, banisters, modeling

board

INDUSTRY DRIVERS

As an example let’s take the Aerospace market

INDUSTRY DRIVERS

Hardware capability is almost there

INDUSTRY DRIVERS

Programming robots is very different than a CNC machine tool

Program

Teach


PROGRAMMING BARRIERS


Task dimension and machine tool kinematics

2D




3D




5X



Tasks are commonly 2-5D



Robots are typically 6D+

6X 7X 9X



A typical 6 axis robot only has rotary axis

• Joint limits are hard to check intuitively

• Robot to part collision is impossible to determine without simulation

• Reach is difficult to check



It is desirable to program a robot in Cartesian coordinates• Robots are commanded in joint values by the robot controller



A 6 axis robot requires position and orientation for each point

(X,Y,Z),(I,J,K)

• Tasks are typically 2-5D• Managing 6D pose is required



Programs must be singularity free• A six axis robot has three singularity zones



A robot has 8 possible configurations for every point



A variety of manufacturing processes (additive/subtractive/forming)



End user requirements (especially for high-mix low batch)



Robot off-line simulation and programming software• More robot centered, less task focused



CAD/CAM Software• More path centered, less robot focused



Technology paradigm shift = Multi-disciplinary team

Software Engineering

Kinematics and Robotics (Hyper real-time calculations)Mathematical Optimization (AI, Deep/Machine Learning)Simulation and User Interaction (Collisions)CAD/CAM (Easy task based programming)


2D Problem

Dimensions of a solution are very important

2D INPUTCOLD WATERHOT WATER

2D OUTPUTFLOW

TEMPERATURE


2D Problem

Dimensions of a solution are very important


2D Problem

Difficult user experience


2D Opportunity

Task and Device independence


TASK BASED PROGRAMMING

Integrated path programming tools (for high-mix low-batch)

Designed for task expert• No CAD/CAM expertise• No robotic expertise

Unique CAD/CAM features• Intuitive graphical interaction• Automated task programming

Unique robot specific features• Robot specific speed settings• Motion optimization• Easy transition tools




EXPERTISE REQUIRED?

Task/Process

Programming and CAD/CAM

Robotics and Simulation

CASE: Trimming of knee braceBEFORE: ManualAFTER: Robotic



IDEAL SOLUTION?

CAD/CAM + Robotic path converter

Robotic off-line programming and simulation

Integrated CAD/CAM for robots

High-mix low-batch programming


TASK SHARING

STRICTLY CONFIDENTIAL – FOR INTERNAL USE ONLYSOURCE: http://video.bonappetit.com/watch/jacques‐pepin‐peels‐an‐apple

Cooperative task sharing

TASK SHARING


Optimized cooperative task sharing

TASK SHARING


Cooperative task sharing

TASK SHARING


Task success is easy with the proper programming tools

TASK SHARING


INDUSTRY 4.0SMART FACTORIES

TD

PC

MI

TD

PC

MI

TD

PC

MI

INDUSTRY 4.0 CAPABLE

Task Distribution

Process Control

Monitoring & Interaction


Networked Behavior

Distributed Learning

Virtual Emulation

Embedded Programming

Hypertherm Robotic Software5929 Trans-Canada HWY, Suite 330St-Laurent, QuebecCanada H4T 1Z6

Tel. +514. 225.2206Fax. +514.221.3661

www.robotmaster.com

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