robotstudio 5.11 document id: 3hac030420-001...

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Operating manualMachining PowerPac

RobotStudio 5.11

Document ID: 3HAC030420-001

Revision: A

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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB’s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2008 ABB All rights reserved.

ABB RoboticsSE-721 68 Västerås

Sweden

Table of Contents©

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Overview .........................................................................................................................................5

1 Introduction 71.1 About Machining PowerPac.......................................................................................................71.2 Terms and Concepts ...................................................................................................................9

2 Installation 112.1 Installing...................................................................................................................................112.2 Getting Started..........................................................................................................................13

3 Navigating Machining PowerPac 153.1 Overview ..................................................................................................................................153.2 The Machining Ribbon-tab ......................................................................................................173.3 The Machining Browser ...........................................................................................................203.4 The Path View ..........................................................................................................................243.5 The Solution Wizard ................................................................................................................28

4 Workflow for Machining PowerPac 294.1 Overview ..................................................................................................................................294.2 How to Create or Modify a Surface .........................................................................................314.3 How to Create Machining Solutions Based on Surface ......................................................34

4.3.1 Launching the Wizard ....................................................................................................344.3.2 Defining Machining Solution.........................................................................................354.3.3 Creating Machining Surface...........................................................................................374.3.4 Setting Machining Process Parameters ..........................................................................384.3.5 Setting Tool and Work Object .......................................................................................424.3.6 Setting Path Generation Pattern .....................................................................................444.3.7 Setting Target and Path ..................................................................................................524.3.8 Previewing the Trajectory of the Tool ...........................................................................55

4.4 How to Create Machining Solutions Based on Edge ...............................................................574.5 How to Set Schedule ................................................................................................................584.6 How to Modify Solutions, Paths and Targets.......................................................................59

4.6.1 Overview ........................................................................................................................594.6.2 Working with the Machining Browser...........................................................................604.6.3 Working with the Path View.........................................................................................62

4.6.3.1 Overview...........................................................................................................624.6.3.2 The Create Menu...............................................................................................644.6.3.3 The Modify Menu .............................................................................................714.6.3.4 The Configuration Menu...................................................................................77

4.6.4 Working with the Machining Ribbon-tab ......................................................................79

3

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4.7 How to Set up a Simulation..................................................................................................... 874.8 How to Export Machining PowerPac Programs...................................................................... 884.9 How to Create or Modify Templates..................................................................................... 90

4.9.1 Overview ....................................................................................................................... 904.9.2 Machining Templates .................................................................................................... 924.9.3 Approach/Departing Templates .................................................................................... 954.9.4 Solution Configuration Templates ................................................................................ 96

4.10 How to Create Calibrations ................................................................................................... 97

5 Trouble Shooting 995.1 About Path Generation Pattern................................................................................................ 99

4

Overview

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Overview

About This ManualThis manual describes how to use Machining PowerPac to create machining programs offline. It also explains Machining PowerPac terms and concepts.

UsageThis manual should be used when working with Machining PowerPac.

Who Should Read This Manual?This manual is intended for RobotStudio users, proposal engineers, mechanical designers, offline programmers, robot technicians and service technicians.

PrerequisitesThe reader should have basic knowledge of:

• Industrial robots and their terminology.

• RAPID programming language.

• RobotStudio.

Organization of ChaptersThe manual is organized in the following chapters:

Chapter Content

1. Introduction Describes terms and concepts of Machining PowerPac.

2. Installation Describes how to install Machining PowerPac.

3. Navigating Machining PowerPac

Describes the graphical user interface of Machining PowerPac.

4. Workflow for Machining PowerPac

Describes how to work with Machining PowerPac.

53HAC030420-001 Revision: A

Continues on next page

Overview

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References

Revision

Reference Document Id

Operating manual - RobotStudio 3HAC032104-001

Application manual - Force Control for Machining 3HAC027595-001

Revision Description

- First edition

A Added information about new functions, for example, the FC_SpeedChangeProcess template, the new pattern Edge that is used to generate paths along the edges of the user-defined surface, and new solution configuration templates for RW Machining FC.

6 3HAC030420-001 Revision: A

1 Introduction1.1. About Machining PowerPac

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OverviewMachining PowerPac is a process specific add-in to RobotStudio. This software product aims to provide a new solution to solve difficulties in programming complex 3D paths offline for the machining process.

Key FeaturesKey features of Machining PowerPac:

Function Description

Path generation based on surface

All the machining paths are created based on a user-defined surface or along the edges of the surface. Which means that a surface must be created before creating machining paths.NOTE! For creating path along edges, creating a surface is also required. And makes sure that the edges you need are included in the surface.

Wizard-based path generation

Provides a wizard where the parameters regarding machining process can be defined. After going through the wizard, a set of machining paths will be created on the surface or along the surface edges.See How to Create Machining Solutions Based on Surface on page 34 for how to use the wizard.

Saving and sharing experience by templates

Provides three types of templates to save the experiential data:• Machining template, contains machining process infor-

mation.• Solution configuration template, contains solution con-

figuration parameters.• Approach/Depart template, defines the approach/

departing styles.All the templates can be shared between different Machining PowerPac users by exporting and importing.See How to Create or Modify Templates on page 90 for how to export or import templates.




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Target orientation optimiza-tion

Provides functions to adjust target frame in both the single target level and the multi-targets level. NOTE! The multi-selected targets must be in the same path.

Multiple export The machining program in the Machining PowerPac can be exported into different formats which can be recognized by different user interfaces.

• RWM, exports the program as RobotWare Machining FC project files which include taught targets to improve learning speed and accuracy.

• RAPID, exports the program into RAPID program.See How to Export Machining PowerPac Programs on page 88 for how to export a machining program.

Function Description


1 Introduction1.2. Terms and Concepts

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1.2. Terms and Concepts

Machining PowerPac ConceptsThe table below describes the terminology and concepts that are used in Machining PowerPac.

Term Explanation

Surface A machining surface is a continuous area that consists of one or more geometrical faces in a same part. In Machining PowerPac, a surface is created to define an area to be machined, then the machining paths can be generated on the surface or along the edge of the surface.

Solution Represents the machining sequence.The paths result in one pattern for a machining surface.It’s possible to create more than one solution for the same surface.

Schedule The entry point of the machining program.

Pattern An algorithm for generating paths on a surface.It shows the idea to users in a user-friendly way and the users do not need to know the details of an algorithm.

FC Acronym for Force Control.

RCS In Machining PowerPac, each target is combined with a local reference coordinate system, which is named Reference Coordinate System (RCS).RCS is primarily used as a helper frame for making it easier to create and manipulate targets.The default RCS is defined

• X axis direction is along the path direction,• Z axis direction is along the normal vector of the surface,• Y axis direction follows the right hand rule.

Tool Working Range Tool working range defines a range of a tool that can be used to machine a work piece.Tool working range is expressed in degree as a angle.

Work Angle Defines how much a target can rotate around the X axis of the RCS with the assumption that the original orientation of the target is aligned with the RCS.



1 Introduction1.2. Terms and Concepts

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Travel Angle Defines how much a target can rotate around the Y axis of the RCS after the target is already rotated within the defined work angle.

Spin Angle Defines how much a target can rotate around the Z axis of the RCS after the target is already rotated with the defined travel angle.

Term Explanation


2 Installation2.1. Installing

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OverviewThis section describes the installation process.

PrerequisitesTo start the installation process, the following must be available:

• A computer that meets or exceeds the system requirements.

• A log on account with administrator rights on the computer.

• RobotStudio installed on the computer.

• Machining PowerPac installation package.

System Requirements To work with Machining PowerPac, the following is required:

Recommended Hardware• CPU: 2.0 GHz Intel Pentium 4 or faster processor

• Memory: 1 GB RAM or more (More is recommended.)

• Available disk space: 5+ GB on the system disk, 250+ MB on the installation disk

• Graphics card: High performance OpenGL-compatible graphics card with the corresponding up-to-date drivers installed

• Screen resolution: 1280 x 1024 pixels (Recommended)

• Colors: 256 or higher

• DPI: Normal size (96 dpi)

• Mouse: Three-button mouse

Software Requirements• Microsoft Windows XP Professional with Service Pack 2, or

• Microsoft Windows Vista - Business or higher

• RobotStudio 5.11




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Installing Machining PowerPac

Installing a LicenseFollow the procedure of installing a license the same as RobotStudio.

Action

1. Browse to Machining PowerPac installation files and double-click the .exe file.The installation wizard opens.

2. Follow the instructions in the installation wizard.

3. When the installation is finished, complete the installation wizard by clicking Finish.


2 Installation2.2. Getting Started

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2.2. Getting Started

How to Start Machining PowerPacFollow these steps to start Machining PowerPac:

1. Create a new station, or open an existing station by using RobotStudio basic function.

2. Click Machining in the PowerPacs group of the Add-ins tab on the Ribbon.

NOTE!Machining PowerPac can not be started with an empty station.

How to Stop Machining PowerPacTo stop Machining PowerPac, click Machining again on the Add-ins tab or click Close Machining in the Quick Access Toolbar.


2 Installation2.2. Getting Started

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3 Navigating Machining PowerPac3.1. Overview

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The Graphical User InterfaceThe graphical user interface of Machining PowerPac contains four main parts as shown in the following pictures:

• The Machining Ribbon-tab on page 17

• The Machining Browser on page 20

• The Path View on page 24

• The Solution Wizard on page 28

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3 Navigating Machining PowerPac3.2. The Machining Ribbon-tab

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3.2. The Machining Ribbon-tab

About the Machining Ribbon-tabThe Machining ribbon-tab contains the controls for creating machining surfaces, solutions and calibrations, modifying machining solutions and paths, exporting, and checking/healing imported parts.

Elements on the Machining Ribbon-tab

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Group Button Description

Create Solution Opens the Solution Wizard to create a machining solution.See How to Create Machining Solutions Based on Surface on page 34 for a more detailed description.

Surface Opens the Create Machining Surface dialog box.See How to Create or Modify a Surface on page 31for a more detailed description.

Calibration Opens the Create Calibration dialog box.See How to Create Calibrations on page 97 for more information.




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Modify Machining Template

Opens a dialog box to change the machining template for the selected path or solution.See Machining Templates on page 92 for more infor-mation.

Approach/Departing Template

Opens a dialog box to change the approach/departing template for the selected path or solution.See Approach/Departing Templates on page 95 for more information.

Machining Speed Opens a dialog box to set speed for the selected path or solution.See Machining Speed on page 81 for more informa-tion.

Machining Force Opens a dialog box to set the machining force for the selected path or solution which does support force control process.See Machining Force on page 83 for more informa-tion.

Tool Compensa-tion

Opens a dialog box to set the tool compensation for the selected path or solution.See Tool Compensation on page 84 for more informa-tion.

Tool Working Range

Opens a dialog box to set the tool working range for the selected path or solution.See Tool Working Range on page 84 for more infor-mation.





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Export RWM Abbreviation for RobotWare Machining Force Control which is a controller software designed to address challenges in machining uneven and unpredictable heavy flashing and gating of castings. See Application manual - Force Control for Machining for detailed description.Exports the current program as a file with specific format that can be recognized by the RobotWare Machining FC graphical user interface.See How to Export Machining PowerPac Programs on page 88 for more information.

RAPID Exports a complete RAPID program.See How to Export Machining PowerPac Programs on page 88for more information.

Diagnostics Check/Heal Checks or heals the imported CAD models.See Check/Heal on page 85 for more information.

General Help Provides information about help and product version.



3 Navigating Machining PowerPac3.3. The Machining Browser

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3.3. The Machining Browser

OverviewThe Machining browser is a hierarchical display of Machining PowerPac items, such as surfaces, schedule, calibrations and templates.

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Icons in the Machining Browser

Icon Node Description

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Task The current robot task.

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Surface collection Contains all the surfaces that are created with Machining PowerPac in the current station.

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Surface A certain user-defined machining surface.

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Solution A set of result paths that are created on the surface.

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Unknown path A path for which the reachability check has not been done.

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Verified path A path where all the targets are reachable for the used robot.

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Failed path A path that contains at least one unreachable target.

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No configuration solution path

A path where no configuration solution can be found.

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Schedule The entry point for a machining program.

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Calibration collection

Contains all calibration data.




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Calibration The transformation method, with which you can transform the programs created in the virtual environment into the real cell.

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Calibration point The points that are used for coordinates transforma-tion.

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Work object The work object that is used during calibration.

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Template collection

Contains different types of templates.

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Machining collection

Contains all machining templates.

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Machining A machining template.

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Approach/Departing collection

Contains all approach/departing templates.

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Approach/Departing template

Defines how a robot approaches or departs the machining surface. Contains both the approach targets and departing targets.

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Approach target list

Contains all the approach targets in the current template.

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Approach target A position and rotation defines how a robot approaches a surface.

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Departing target list

Contains all the departing targets in the current template.





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Departing target A position and rotation defines how a robot departs a surface.

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Solution configu-ration collection

Contains all templates of solution configuration.

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Solution configu-ration

A template contains all the information about solution configuration.



3 Navigating Machining PowerPac3.4. The Path View

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3.4. The Path View

OverviewThe Path View displays all targets in a path by representing them with instruction icons.

When a program contains several paths, the first instruction in the Path View is the last instruction of the preceding path. This is used to verify that the robot can bridge these paths.

A robot icon, that is the robot cursor, sits on top of the targets to indicate the position of the robot in the target sequence. Note how the cursor advances step-by-step when the path is executed.

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Path View ToolbarThe Path View holds the Path View Toolbar, which has menus and buttons for the most frequently used commands.

Icon Description

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View Center sets the view center automatically to the selected target in the path view or the active TCP (if no target is selected).

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Select All selects all the paths in the Path View.

The Create menu See The Create Menu on page 64.

The Modify menu See The Modify Menu on page 71.




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The Configura-tion menu

Contains two commands:• Check Reachability, displays whether the robot can reach a target

and motion instruction by changing the targets’ color. A successful result turns the target yellow, while an unsuccessful result turns it red.

• Set Configuration, see Set Configuration on page 77.

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Arm Configuration opens a dialog box similar to the one opened by clicking Configuration, Set Configuration.See also Set Configuration on page 77.The image on Arm Configuration also indicates the active arm config-uration of the target.

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Wrist Configuration opens a dialog box similar to the one opened by clicking Configuration, Set Configuration.See also Set Configuration on page 77.The image on Wrist Configuration also indicates the active wrist con-figuration of the target.

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Tool Configuration opens a dialog box similar to the one opened by clicking Configuration, Set Configuration.See also Set Configuration on page 77.The image on Tool Configuration also indicates the active tool configu-ration of the target.

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Jump to jumps the robot to the selected target and checks for reach. A successful result turns the target yellow and moves the robot one discrete step towards the target. An unsuccessful result turns the target red and leaves the robot in its current position.

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Move to moves the robot from the previous target to the selected target, checks for reach and sets the robot configuration. A successful result turns the target green and moves the robot continuously towards the target. An unsuccessful result turns the target red and leaves the robot in its current position.NOTE! The virtual controller is not running when executing this command.

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Simulation synchronizes the selected targets to the virtual controller and executes the selected targets in the virtual controller.

Icon Description




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Instruction Icons

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Stop stops the current robot motion.

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The Speed drop-down list applies only to Jump to and Move to. The simulation speed is determined by the RAPID program.

Icon Description

Object Description

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Path Divider.Indicates the start of a path.

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Approach Target

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Start Target

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Air/Via Target

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End Target

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Departing Target

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Linear Move

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Joint Move




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The color coding:

Color Status

White Unknown status.

Green Target verified.

Yellow Solution found, but not verified.

Red No solution, or target out of reach.


3 Navigating Machining PowerPac3.5. The Solution Wizard

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3.5. The Solution Wizard

How to Launch the Solution WizardTo launch the Solution Wizard, click Solution on the Machining ribbon-tab.

Wizard PagesThe Solution Wizard is a 7-step wizard, where a machining solution can be quickly created.

Related InformationHow to Create Machining Solutions Based on Surface on page 34.

Page Action

1. Machining Solution Select a controller, task, solution and configuration template for the solution on this page.

2. Machining Surface Define a surface on which the machining paths will be created. There are two ways:

• Select an existing surface from the drop-down list.• Create a new surface by selecting continuous

faces in the 3D view.

3. Machining Process Parameters

Set parameters for generating robot targets and paths.

4. Tool and Work Object Select and set a work object and tool data for the current solution.

5. Path Generation Pattern Select a path generation pattern and set parameters for the selected pattern.

6. Target and Path Set the target orientation and select a path connection type.

7. Preview Preview the trajectory of the tool.


4 Workflow for Machining PowerPac4.1. Overview

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OverviewThe following is a recommended flow for working with Machining PowerPac. After you complete the workflow, you can perform these task in any order.

NOTE!The machining station (contains at least one robot system) should be set up by using RobotStudio basic function before starting Machining PowerPac, as the Machining PowerPac provides only a method for creating paths but not functions for building stations.

Workflow for Machining PowerPacAfter starting Machining PowerPac, follow these steps:

Task Description

1. Create a surface to be machined.

See How to Create or Modify a Surface on page 31.NOTE! For creating path along edges, creating a surface is also required. Define a surface that includes the edges you need before creating paths.

2. Create a machining solution. Create a set of machining paths with the Solution Wizard.NOTE! A solution must be created for a certain surface. You can choose to create a surface by clicking Surface on the Machining ribbon-tab, or to create a surface within the wizard.For more information, see How to Create Machining Solutions Based on Surface on page 34 and How to Create Machining Solutions Based on Edge on page 57.

3. Configure paths. Open paths in the Path View, select all targets and click Move to to find configurations for all targets, and execute the whole path.If any target can not be executed, manually adjust the target.For more information, see How to Modify Solutions, Paths and Targets on page 59.




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4. Synchronize to virtual controller. Synchronize all the paths in the current station to the virtual controller.For more information, see How to Set up a Simulation on page 87.

5. Run simulation. Run simulation to make sure that all paths can be executed in the virtual controller.For detailed information, see How to Set up a Simulation on page 87.

6. Export the whole program. The program can be exported in two different formats.For detailed information, see How to Export Machining PowerPac Programs on page 88.

Task Description


4 Workflow for Machining PowerPac4.2. How to Create or Modify a Surface

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4.2. How to Create or Modify a Surface

OverviewThis section describes how to create a machining surface.

Creating a SurfaceClick Surface on the Machining ribbon-tab, the Create Surface dialog box opens as illustrated below.

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To create a surface, follow these steps:

1. Click Surface on the Machining ribbon-tab to open the Create Surface dialog box.

2. Enter a name in the Name text box or use the default one for the new surface.

Item Description

Name The name of the new surface.

Select Faces from 3D view

All the faces that are selected by clicking in the 3D view are displayed in the box. The new surface is made of these faces.

Clear Clears all the faces in the Select Faces list box.

Create Creates a new surface according to the settings in this dialog box.

Close Closes this dialog box.




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3. Select faces by clicking in the 3D view. It is possible to multi-select faces in the 3D view by pressing SHIFT while clicking each in the 3D view. The selected faces will be added to the list under Select Faces from 3D view. Make sure that the selected faces are continuous.

4. Right-click each face name in the faces list and click Examine from the shortcut menu to view the selected face in the center of the 3D view. If you are not satisfied with the face, click Remove from the shortcut menu to remove the selected face from the face list.

5. Click Create, the surface that consists of all the faces in the list will be created. You may then browse the new surface in the Machining browser.

You can also create a surface when using Solution Wizard. For more information, see How to Create Machining Solutions Based on Surface on page 34.

Modifying a Surface

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Item Description

Name Displays the name of the selected surface.NOTE! Unable to rename an already created surface.

Faces Lists all the faces that the selected surface contains.




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To modify a surface, follow these steps:

1. Right-click a surface in the Machining browser and click Properties... to open the Properties: Surface dialog box.

2. Add new faces to the Faces list by clicking in the 3D view, or remove faces by right-clicking a face and clicking Remove from the shortcut menu.

3. Click Apply.

The changes will take effect.

NOTE! The changes will not make any influence on the solutions and paths that were created based on the previous surface.

Examine Shortcut menu item. Displays the selected face in the center of the 3D view.

Remove Shortcut menu item.Removes the selected face.

Apply Makes the changes take effect.

Close Close this dialog box.

Item Description


4 Workflow for Machining PowerPac4.3.1. Launching the Wizard

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4.3 How to Create Machining Solutions Based on Surface

4.3.1. Launching the Wizard

OverviewMachining PowerPac provides a wizard that contains all necessary parameters for creating machining solutions. After you go through the wizard, a machining solution is created.

How to Launch the WizardClick Solution on the Machining ribbon-tab to launch the wizard.

TIP!When editing parameters in this wizard, an indicator appears indicating which item is being edited, and the illustration and description for the current edited item will be displayed on the right side of the wizard.


4 Workflow for Machining PowerPac4.3.2. Defining Machining Solution

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4.3.2. Defining Machining Solution

Description

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Item Description

Controller Select a controller in which the solution will be located.

Task Select a task in which the solution will be located.

Solution Configuration Template

Select a solution configuration template to load the parameters that were set previously for creating a solution. If no template is selected, all the parameters will have the default value.

Solution Name Enter a name for the new solution in the text box.



4 Workflow for Machining PowerPac4.3.2. Defining Machining Solution

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Follow these steps:

1. Select a controller that will be used for the solution from the Controller drop-down menu.

2. Select a task from the Task drop-down menu.

3. Select a solution configuration template to load and reuse the values and settings that are defined in the selected template or select Empty then enter value for each parameter manually.

4. Enter a name for the solution or use the default name.

5. Click Next to continue to the next page.


4 Workflow for Machining PowerPac4.3.3. Creating Machining Surface

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4.3.3. Creating Machining Surface

Description

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Follow these steps:

1. Click the drop-down menu and select an existing surface name or select Create New Surface.


Item Description

Machining surface Select an existing surface or create a new surface.See How to Create or Modify a Surface on page 31.

Name New surface name.

Select Faces from 3D view A list of faces selected from the 3D view. The new surface consists of these faces.


4 Workflow for Machining PowerPac4.3.4. Setting Machining Process Parameters

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4.3.4. Setting Machining Process Parameters

Description

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Item Description

Tolerance (mm) Controls how the generated path fits with the surface. A set of polygon lines corresponding to a set of move instruc-tions are used to fit the surface. The value defines the maximum distance between a polygon line and the surface. If the value is 0, this parameter is ignored.This value should be 0 - 1000 mm.

Deviation Angle (deg) Controls the fitness of the robot path with the surface.The maximum allowable angle between the tangent lines of 2 adjacent points in a path. If the value is 0, this parameter is ignored.The value should be 0 - 360 degree.




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Follow these steps:

1. Click the up/down arrow to set a desired value or enter a desired value for each parameter according to the real working condition.

2. Select a machining template for the solution.

3. If the force control process type is applied to the current solution, click Set Force Control Parameters to open a dialog box to set values for force control parameters as displayed below.


Machining Overlap Rate(%)

The overlapping strip between two adjacent paths which is defined as the percentage of the used tool width.The minimum value is 0 which means no overlap between two adjacent paths. The maximum is 99 which means 99% overlapped between two adjacent paths.

Machining Template Defines a set of specific move instructions. The template can be customized in terms of machining process related properties, such as properties of each included move instruction and number of move instructions of different parts of a path.See Machining Templates on page 92 for more information.

Set Force Control Parameters

Opens a dialog box containing force control parameters.

Enable Optimize Speed Enables or disables the function of setting optimal speed.

Maximum speed on surface

The maximum speed will be applied to the machining point on the surface with the largest curvature.

Minimum Speed on surface The minimum speed will be applied to the machining point on the surface with the smallest curvature.

Item Description




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If you select FC_PressureProcess template, after click Set Force Control Parameters, the dialog box opens.

See Application manual - Force Control for Machining, section FCPress1LStart, for the description about the parameters of FC Pressure Start, section FCPressL and FCPressC for the description about the parameters of FC Pressure Via, and section FCPressEnd for the description about the parameters of FC Pressure End.

en0700000260




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If you select FC_SpeedChangeProcess template, after click Set Force Control Parameters, the dialog box opens.

See Application manual - Force Control for Machining, section FCSpdChgAct, for the description about the parameters.

en0700000261


4 Workflow for Machining PowerPac4.3.5. Setting Tool and Work Object

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4.3.5. Setting Tool and Work Object

Description

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Item Description

Work Object Defines the work object to be used for this path. An existing work object can be selected from this list, or a new work object can be created as the default one, which will be attached to the work piece to be used for the path.

Tool Type Defines the type of circular tool according to its working area.Two types of tools are supported:

• Side working, the surrounding face will be used.• Face working, the top face will be used.

Tool Data Defines the tool data that is used for all move instructions in the path.

Tool Working Width (mm) Defines the working range of the tool, which means the contacting length of the tool’s working face with the machined face.The value should be from 1 to 10000.



4 Workflow for Machining PowerPac4.3.5. Setting Tool and Work Object

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Follow these steps:

1. Enter a desired value for each parameter.


Tool Compensation (mm) For side working tool, tool compensation means the radius of the tool wheel. This is because the TCP is defined to align with the rotating axis of the tool, while the contacting points of the tool are located at the surrounding face;For face working tool, tool compensation means the distance from the top face of the tool to the machining face. Value equal to zero means the tool face will be in contact with the machined face. The value can only be zero or positive.The value should be from 0 to 10000.

Path Merging Gap (mm) Path Merging Gap means that two robot motion segments will be integrated as one if the gap between them is less than the specified value.The value should be from 0 to 10000.

Item Description


4 Workflow for Machining PowerPac4.3.6. Setting Path Generation Pattern

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4.3.6. Setting Path Generation Pattern

Description

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Item Description

Select Pattern drop-down list

Provides six different patterns for creating machining paths.When creating paths with targets based on the object geometries, curves are the geometrical objects that RobotStudio uses. Five patterns are provided on this page to create curves that generate paths along the curves, instead of manually finding and creating the necessary targets.

Editing area Contains the related parameters for each patterns.




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Cutting Plane Along Straight Line

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First specify a straight line., then generate a set of planes that run perpendicular to the straight line with a constant gap which are defined by the tool working width and overlap rate. These planes will be used to intersect with the machining surface to generate a set of curves. Targets and machining paths will then be generated from these curves.

If one of the generated plane covers the machining surface, the machining targets and paths will be generated along the surface edge.




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Object Description

Direction (In Part Coordinate)

Defines the direction of the straight line where a set of cutting plane are created.Select a direction from the drop-down list.If you are not satisfied with the result, click the left/right arrow or enter a value in each box to adjust the rotation around the X, Y or Z axis. The result can be viewed from the 3D view.

Start and End Point Defines a range in the line alone which the cutting planes can be created.Click left/right arrow or enter desired values to define the start point and end point.The result can be viewed from the 3D view.




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Cutting Plane Along Customized Line

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First specify a feature line, which can be a straight line or a line with several straight line segments, by creating at least two points in 3D view. A set of planes will be generated that run perpendicular with the feature line with a constant gap which are defined by the tool working width and overlap rate. These planes will be used to intersect with the machining surface to generate a set of curves. Targets and machining paths will then be generated from these curves.

Object Description

Feature Line Points (In Part Coordinate)

To add points to the feature line points list:• Click on the surface from the 3D view.

To set point sequence:• Select a point, and click up/down arrow.

To delete points:• Click the "×" to delete the selected point.• or click Clear All Points to delete all the points.

Change Customized Line as Spline

Select this check box to make the customized line flat and pliable.

Change Customized Line as Loop

Select this check box to make the customized line as a loop.




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Circular Cutting Planes

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Use a Group of raying planes that cut the machining surface to create some curves. Create targets and paths on these curves. These paths are machining paths. Here you need to specify the planes’ common axis.

Object Description

Axis Direction (In Part Coordinate)

Defines the direction of the axis.Select an item from the drop-down list to quick adjust the direction.If you are not satisfied with the result, click the left/right arrow or enter a value to adjust the rotation around the X, Y or Z axis. The result can be viewed from the 3D view.

Axis Point (In Part Coordinate)

Click in the 3D view or enter desired value to set the position of the axis point.

Radius Enter a value.




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ISO Parametric Lines

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The machined surface can be regarded as a spine face represented by U and V curves. Where a U curve or a V curve will be located is determined by the value of the parameter that ranges from 0 to 1. A U curve or a V curve can be regarded as a feature line. A set of planes that runs perpendicular to the feature line will be generated with a constant gap which is defined by the tool working width and overlap rate. These planes will then be used to intersect with machining surface to generate a set of curves. Targets and machining paths will be generated from these curves.Two curves that stay in different faces will be integrated as one if the distance between them is less than the defined merging gap. This will be enabled when the check box is marked.

Object Description

Feature Line Parameter All the faces that the surface contains are displayed here.The

V direction Select the check box of V direction, the V direction should be used. Clear the check box, the U direction will be used.

Location Enter a desired value for each face. The range should be from 0 to 1.




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Customized Points

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Generate targets on the surface at the place you clicked and generate a path with all these targets according to the clicking sequence.

A machining path will be created by tracing the points in sequence.

Object Description

Customized Points (In Part Coordinate)

To add points to the points list:• Click on the surface from the 3D view.

To set point sequence:• Select a point, and click up/down arrow.

To delete points:• Click the "×" to delete the selected point.• or click Clear All Points to delete all the points.

Change Customized Line as Spline

Select this check box to make the generated path flat and pliable.

Change Customized Line as Loop

Select this check box to make the generated path as a loop.




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Edges

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Generate targets on the surface along the selected edge and generate a path with all these targets according to the edge sequence.

Object Description

Select edge from 3D view To add edges to the list:• Click to select edges from the 3D view.

To set edge sequence:• Select an edge, and click the up/down arrow.

To delete points:• Click the "×" to delete the selected edge.• or click Clear All Points to delete all the edges.


4 Workflow for Machining PowerPac4.3.7. Setting Target and Path

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4.3.7. Setting Target and Path

Description

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Item Description

Work Angle (deg) Defines targets orientation. See Terms and Concepts on page 9.

Travel Angle (deg) Defines targets orientation. See Terms and Concepts on page 9.

Auto Calculate Spin Angle The Machining PowerPac will find a spin angle automatically.

Spin Angle (deg) See Terms and Concepts on page 9.

Offset (mm) The distance in axis direction between the target location and the reference coordination frame.




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Path Connection Type Defines how different paths can be connected.Three types are provided:

• Clipping

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• Sweeping

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• Miniclipping

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A template that defines how a robot approaches/leaves a part.NOTE! The approach points are relative to the first machining point and the departing points are relative to the last machining point.

Item Description




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Follow these steps:

1. Enter a desired value for each parameter.


Protect Distance in Path Start (mm)

Distance between the first machining target and the surface edge.The value should be from 0 to 10000.

Protect Distance in Path End (mm)

Distance between the last machining target and the surface edge.The value should be from 0 to 10000.

Item Description


4 Workflow for Machining PowerPac4.3.8. Previewing the Trajectory of the Tool

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4.3.8. Previewing the Trajectory of the Tool

Description

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Item Description

Merge into One Path Merges the generated paths into one machining path which contains all the targets and instructions and keeps the same targets sequence.

Auto Path Configuration Configures the paths automatically after clicking Finish.

Synchronize to Virtual Controller

Synchronizes the current solution to the virtual controller auto-matically after clicking Finish.When the check box of Synchronize to Virtual Controller is selected, the Auto Path Configuration is selected automatically, which means that you cannot synchronize all your settings in the wizard before configuring the paths correctly.

Save Setting as Template Saves all the settings and parameters in the current solution as a template.



4 Workflow for Machining PowerPac4.3.8. Previewing the Trajectory of the Tool

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Follow these steps:

1. If there are some settings that do not meet your requirements, click Back to the relative page.

2. If you want to reuse all the settings for other solutions, click Save Settings As Template... .

3. Click Finish.

After clicking Finish, the solution will be created and the wizard will be closed. You can modify the solution with the Machining ribbon-tab, the Machining browser, and the Path View. See Working with the Machining Ribbon-tab on page 79,Working with the Machining Browser on page 60, and Overview on page 62.


4 Workflow for Machining PowerPac4.4. How to Create Machining Solutions Based on Edge

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4.4. How to Create Machining Solutions Based on Edge

Launching the Solution WizardClick Solution on the Machining ribbon-tab to launch the Solution Wizard.

Setting Parameters See How to Create Machining Solutions Based on Surface on page 34 for how to use the wizard creating solutions.

NOTE! The only difference is that creating solution based on edge must use the Edges pattern. See Edges on page 51for the detailed information.


4 Workflow for Machining PowerPac4.5. How to Set Schedule

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4.5. How to Set Schedule

OverviewThis section describes how to organize all solutions in a schedule.

Schedule is the entry point for a machining program. The new created solution will be added under the schedule node automatically.

Organizing Solutions in a ScheduleWhen a solution is created by the Solution Wizard, this solution will be added under the Schedule node automatically.

To reset the schedule:

• Right-click the Schedule node, click Clear to remove all the solutions. Or right-click the solution that you want to remove from the schedule, and click Remove.

• Add solutions to the schedule by dragging a solution under the surface node and dropping.

• Set solution sequence by right-clicking the solution under the Schedule node and clicking Move up and Move down on the shortcut menu.


4 Workflow for Machining PowerPac4.6.1. Overview

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4.6 How to Modify Solutions, Paths and Targets

4.6.1. Overview

OverviewThis section describes how to modify solutions, paths and targets. Frequently used functions are provided, such as remove, rename, reverse and so on. You can modify an element by right-clicking the element node or clicking the button on the Machining ribbon-tab.


4 Workflow for Machining PowerPac4.6.2. Working with the Machining Browser

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4.6.2. Working with the Machining Browser

OverviewThe machining solution is automatically displayed in the Machining browser after finishing the Solution Wizard. You can directly synchronize the solution to virtual controller and run simulation, or do some modification with the shortcut menu by right-clicking the solutions and paths in the browser.

Shortcut Menu from the Task Node

Shortcut Menu from the Solution Node

Item Description

Refresh Refreshes the display of the task node.

Clean VC Removes all user modules from the virtual controller.

Synchronize to VC Synchronizes the current program to the virtual controller.

Item Description

Open In Path View Displays all the paths of this solution in both the path view and the 3D view.

Auto Path Configuration Configures paths automatically.

Reverse All Reverses the paths sequence.

Show All in 3D Displays all the paths in the 3D view.

Rename Prompts you to rename the selected solution.

Remove Deletes the selected solution from the current surface node.

Properties... Displays the properties of the selected solution.

Close Path View Closes the paths in the path view.Only available when there are paths opened in the path view.

Hide All Hides paths of the selected solution that were highlighted in the 3D view.Only available on the solution that contains several highlighted paths.



4 Workflow for Machining PowerPac4.6.2. Working with the Machining Browser

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Shortcut Menu from the Path Node

Item Description

Open in Path View Displays the selected path in both:• path view. See Overview on page 62for more informa-

tion.• 3D view, all the targets in the path will be displayed with

reference frames. A tool indicator will show how the tool reaches the targets.

Not available on an open path.

Auto Path Configuration Configures the selected path automatically.

Reverse Reverses the targets sequence in the selected path.

Show in 3D Highlights the selected path in the 3D view.

Rename Allows you to rename the selected path.

Remove Deletes the selected path.

Hide Hides the path that was highlighted in the 3D view.Only available on the highlighted path.

Close Path View Closes the path from the path view.Only available on an open path.


4 Workflow for Machining PowerPac4.6.3.1. Overview

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4.6.3. Working with the Path View

4.6.3.1. Overview

OverviewThe path view displays the targets in a path by representing them with instruction icons. These target can be modified by using commands from the shortcut menus or the buttons in the path view tool bar.

You can choose to modify:

• An individual target.

• An entire path.

• Multi-selected targets.

Shortcut Menu from the Path ViewRight-click an instruction icon in the Path View to open the shortcut menu. The contents of the shortcut menu will change depending on selected target.

The table below shows all the commands in the menu.

en0700000254

Object Description

Create Creates paths, instructions and procedure calls. The content will change depending on selected target.Not available for the approach target, departing target, end target and multi-selected targets.See The Create Menu on page 64 for detailed description.



4 Workflow for Machining PowerPac4.6.3.1. Overview

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Path View ToolbarThe path view holds the path view toolbar, which has menus and buttons for the most frequently used commands.

See The Path View on page 24 for detailed description.

Related InformationThe Path View on page 24

Modify Modifies targets, instructions and motion type. The content will change depending on selected target.See The Modify Menu on page 71.

Configuration Contains the following commands:• Check Reachability on page 77• Set Configuration on page 77

Jump to See Path View Toolbar on page 24.

Move to See Path View Toolbar on page 24.

Set target reference as UCS

Sets the target referenced in the instruction as the User Coordinate System.Not available for the multi-selected targets.

Delete Deletes the selected item.

Select this path Selects the entire pat.Only available for the path divider.

Object Description


4 Workflow for Machining PowerPac4.6.3.2. The Create Menu

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4.6.3.2. The Create Menu

OverviewThis menu contains the following commands:

en0700000255

Command Description

New Path Only available for the path divider.Create a New Path on page 66

Machining Instruction Only available for the Start or Via target.Create a Machining Instruction on page 67

Air Instruction Only available for a path divider, action instruction, or ABS joint instruction. Create an Air Instruction on page 68

ABS Joint Instruction Only available for a path divider, action instruction, or ABS joint instruction.Create an ABS Joint Instruction on page 69

Action Instruction Only available for a path divider, action instruction, or ABS joint instruction. Create an Action Instruction on page 70

Procedure Call Only available for a path divider, action instruction, or ABS joint instruction. Create a Procedure Call on page 70




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NOTE!• The contents of the Create menu will change depending on selected target.

• Save the parameters and settings in the present tool window before clicking the Create menu, otherwise all these settings will be lost. Because to open any Create dialog box will close all other dialog boxes that were previously opened.

• Save the parameters in the Create dialog box before opening other dialog boxes, otherwise the Create dialog box will close and all the parameters in the Create dialog box will be lost.

Add Approach Instruction Only available for the Start target when the path does not contain approach targets.Adds approach targets before the Start target according to the current used Approach/Departing template.

Add Departing Instruction Only available for the End target when the path does not contain departing targets.Adds departing targets after the End target according to the current used Approach/Departing template.

Command Description




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Create a New Path

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To create a new path, follow these steps:

1. Right-click a path in the Path View, in the Create menu, click New Path.

2. Name the new path or use the default name in the Name text box.

3. Select a Machining template and an approach/departing template for the path.

4. Set work angle, travel angle and spin angle for the path.

5. Click in the 3D view to add points to the new path.

6. Click Create, the new path will be created.




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Create a Machining Instruction

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Machining instruction defines how the robot moves to the via target which must locate on the surface to be machined.

To create a Machining instruction, follow these steps:

1. Select a reference frame from the drop-down list.

2. Click in the 3D view to set a To Point, the position value of the selected target is displayed in the dialog box.

3. Click Create, the new machining instruction is created.




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Create an Air Instruction

en0700000217

Air instruction defines how the robot moves to an air target which is the intermediate target between path section.

To create an Air Instruction, follow these steps:

1. Select a desired item from the Reference drop-down list.

2. In the 3D view, move the robot TCP to the desired position and click Present. A new target is displayed in the graphics window, and an instruction icon is added to the path view.

3. To set the position manually, select a reference coordinate system, enter a desired value.

4. In the dialog box, click OK. If the Auto Create check box is selected, the air instruction is automatically created when a valid input has been entered. A new target is displayed in the 3D view, and an instruction icon is added to the path view. Click OK, all the changes will take effect.

5. Click Close to close this dialog box without any changes.




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Create an ABS Joint Instruction

en0700000246

Absolute joint instructions may be added to a path.

To create a jointtarget, follow these steps:

1. Jog the robot to an arbitrary position and then click OK.

2. A new jointtarget is displayed in the 3D view, and an instruction icon is added to the path view.




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Create an Action Instruction

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To create an action instruction:

1. Select an instruction from the drop-down list.

2. Click OK, a blue instruction is add to the path view.

Create a Procedure Call

en0700000248

To set procedure call:

1. Select a path procedure name from the drop-down list.

2. Click OK to make the changes take effect.


4 Workflow for Machining PowerPac4.6.3.3. The Modify Menu

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4.6.3.3. The Modify Menu

OverviewThis menu contains the following commands:

en0700000256

Command Description

Instruction Not available for the path divider.Modify Instruction on page 73

Target Not available for a path divider, ABS joint target, or action instruction. Modifying Target on page 74

Convert to Linear Move Only available for a Approach, Departing or air target with joint motion.

Convert to Joint Move Only available for a Approach, Departing or air target with joint motion.

Convert to Air Instruction Only available for the first Approach target or the last Departing target.

Convert to Approach Instruction

Only available for an air target, after which the target must not be air.

Convert to Departing Instruction

Only available for an air target, before which the target must not be air.




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The Modify menu for the multi-selected targets contains the following command:

NOTE!The contents of the Modify menu will change depending on selected target.

Command Description

Target Reference Position on Selection

Target Reference Position on Selection on page 75

Target Reference Orientation on Selection

Target Reference Orientation on Selection on page 76

Target Offset/Angle on Selection

Target Offset/Angle on Selection on page 76

Convert to Circular Only available when two Via targets are selected.

Convert to Linear Only available when two Via targets are selected.




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Modify InstructionMost instructions have arguments that specify how the instruction must be performed. For example, the arguments of the MoveL instruction specify the speed and accuracy with which the robot moves to the target. In the Modify Instruction dialog box, you can display and change these arguments.

en0700000222

Enter the desired value, or select a value from the drop-down menu. Click Apply to make all changes take effect.




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Modifying Target

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To modify the selected target:

1. Reference, the coordinate system of the target reference. All available frames in the station are listed.

2. Target reference, marks the start or end position and rotation.

3. Target, normally linked to the target reference coordinate system. The offset values are relative to the target reference.

Convert to Joint MoveConvert a MoveJ instruction to a MoveL instruction.

Convert to Linear MoveConvert a MoveL instruction to a MoveJ instruction.

Convert to Air InstructionSwitch the motion type of the selected target to Air Instruction.




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Target Reference Position on Selection

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Modify menu on the multi-selected targets.

To modify the selected targets:

1. Reference, the coordinate system of the target reference. All available frames in the system are listed here. Select a desired item from the drop-down list.

2. Position, enter desired values. If you want to move the selected target in just one direction, clear the check boxes of the other axes on the left side.




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Target Reference Orientation on Selection

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Target Offset/Angle on Selection

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This command offsets of rotates the selected targets of process instructions a given distance or angle. This offset or angles is in relation to the target reference coordinate system.


4 Workflow for Machining PowerPac4.6.3.4. The Configuration Menu

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4.6.3.4. The Configuration Menu

Check ReachabilityClick this item to check whether the robot can reach a target. A successful result turns the target yellow, while an unsuccessful result turns it red.

Set ConfigurationRobot configuration may be set for individual targets. The system calculates a configuration based on your selections, after which values are displayed.

Click Configuration -> Set configuration..., the following box appears:

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Item Description

Arm The group is used to specify whether the robot wrist is in front of or behind axis 1, and whether the elbow is up or down.

Wrist This group is used to specify whether axis 4 will be turned positive or negative.



4 Workflow for Machining PowerPac4.6.3.4. The Configuration Menu

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To set configuration, follow these steps:

1. Right-click a target in the Path View, and click Configuration -> Set configuration... from the shortcut menu to start the Set Configuration dialog box.

2. Select a configuration in the New drop-down list or click items in the Arm, Wrist and Tool groups to set configuration manually. An available configuration will turn the corresponding item to white, while the unavailable configuration appears shades.

3. Click Apply.

The configuration will be applied to the selected target.

Tool This group is used to specify whether axis 6 will be turned positive or negative. If neutral is selected, the configuration of axis 6 will be determined by the arm and wrist selections.

New This list displays the configuration and joint values for a selected configuration, as well as alternatives.

Current This box displays the configuration currently stored in the selected target.

Change This box calculates the difference in joint values between the currently selected target and the preceding target in the path.

Item Description


4 Workflow for Machining PowerPac4.6.4. Working with the Machining Ribbon-tab

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4.6.4. Working with the Machining Ribbon-tab

OverviewThe frequently used commands for modifying solutions or paths are provided on the Machining ribbon-tab.

This section introduces the functions that are provided in the Modify group and Diagnostics group.

See How to Create Machining Solutions Based on Surface on page 34, How to Create or Modify a Surface on page 31 and How to Create Calibrations on page 97for the descriptions about the Create group, and How to Export Machining PowerPac Programs on page 88for the description about the Export group.

Machining Template

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To change the Machining template of a path or a solution, follow these steps:

1. In the Machining browser, click a solution that needs to be modified.

2. Click Machining Template on the Machining ribbon-tab to open the dialog box.NOTE! When the dialog box opens, the corresponding values of the selected path or the first path in the selected solution (depending on what you select) will be loaded and displayed in the dialog box.

3. Select a desired template from the Machining Template drop-down list.

4. Click Apply.




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The RAPID instructions of the corresponding targets in the selected path will be changed according to the new Machining Template. For example, if you change the machining template from NormalProcess to FC_PressureProcess, the instruction for the process start target will be changed from MoveL to FCPress1LStart.

See Machining Templates on page 92 for the definition for Machining Template.

NOTE!A Machining template should be applied to an entire solution. After the FC_PressureProcess or FC_SpeedChangeProcess template is applied to the selected solution, the force control parameters in the selected solution will be set to default values.


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To change the Approach/Departing Template of a path or a solution, follow these steps:

1. In the Machining browser, click a path or a solution that needs to be modified.

2. Click Approach/Departing Template on the Machining ribbon-tab to open the dialog box.NOTE! When the dialog box opens, the corresponding values of the selected path or the first path in the selected solution (depending on what you select) will be loaded and displayed in the dialog box.

3. Select a desired template from the drop-down list.

4. Click Apply.




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Changing the Approach/Departing Template will delete the approach/departing targets that were created previously in the selected path then insert new approach/departing targets according to the new template.

See Approach/Departing Templates on page 95 for the definition for Approach/Departing Template.

Machining Speed

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To modify the speed for a path or a solution, follow these steps:


2. Click Machining Speed on the Machining ribbon-tab to open the dialog box. NOTE! When the dialog box opens, the corresponding values of the selected path or the first path in the selected solution (depending on what you select) will be loaded and displayed in the dialog box.

3. Select a desired speed value for each phase.

4. Click Apply.

The new values are applied to the corresponding targets in the selected paths.

See Machining Templates on page 92 for the detailed explanation about the targets classification.

NOTE!Not every paths contains all the types of targets. The speed values can only be applied to the targets that exist in the selected path. For the target type that does not exist in the select path, nothing will be changed in the path even if you set a new speed value.




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Machining Force

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When the Machining FC option is active in the current controller system, the machining force needs to be set.

To modify the machining force for a path or solution, follow these steps:

1. In the Machining browser, click a solution that needs to be modified.

2. Click Machining Force on the Machining ribbon-tab to open the dialog box.NOTE! When the dialog box opens, the corresponding values of the selected path or the first path in the selected solution (depending on what you select) will be loaded and displayed in the dialog box.

3. Enter a desired value under Machining force.

4. Click Apply.

The new value of machining force is applied to the selected path. This value is used in FCPressL or FCPressC when the FC_PressureProcess is selected, or FCSpdChgAct when the FC_SpeedChangeProcess is selected.

NOTE! This command is available only when the FC_PressureProcess or FC_SpeedChangeProcess template is applied to the current solution.




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Tool Compensation

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To modify the tool compensation for a path or a solution, follow these steps:


2. Click Tool Compensation on the Machining ribbon-tab to open the dialog box.NOTE! When the dialog box opens, the corresponding values of the selected path or the first path in the selected solution (depending on what you select) will be loaded and displayed in the dialog box.

3. Enter a desired value under the Tool compensation (mm).

4. Click Apply.

The new value is applied to the selected path and is used to change the offset in Z direction of all the targets in the selected path.

See Setting Tool and Work Object on page 42for the explanation for what the tool compensation is.

Tool Working Range

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To modify the tool working range for a path or a solution, follow these steps:


2. Click Tool Working Range on the Machining ribbon-tab to open the dialog box.NOTE! When the dialog box opens, the corresponding values of the selected path or the first path in the selected solution (depending on what you select) will be loaded and displayed in the dialog box.

3. Select the check boxes of Tool Working Range (deg) and Rotate Tool Working Point (deg), and enter desired values.

4. Click Apply.

The new value is applied to the selected path. Consequently, the spin angles for all the targets in the selected path are changed according to the changes.

See Terms and Concepts on page 9 for the definition of tool working range.

Check/HealThis tool is used to check whether the imported part is valid, and furthermore, to heal the damaged part in the current station. And this function can be available whenever working with Machining PowerPac.

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To check an imported part, follow these steps:

• Click Check/Heal on the Machining ribbon-tab to open the dialog box.

• Select a part that you want to check from the Part drop-down list. All the parts that are imported to the current station will be displayed in the list.

• Click Check.




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The check result is displayed in the Output window.

To heal an imported part, follow these steps:

• Click Check/Heal on the Machining ribbon-tab to open the dialog box.

• Select a part that you want to heal from the Part drop-down list. All the parts that are imported in the current station will be displayed in the list.

• Click Heal.

The result is displayed in the Output window.


4 Workflow for Machining PowerPac4.7. How to Set up a Simulation

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4.7. How to Set up a Simulation

How to run a simulationTo run a simulation follow these steps:

1. Synchronize the current program to virtual controller. This can be done by right-clicking the task node in the Machining browser and selecting Synchronize to VC from the shortcut menu, or selecting the check box Synchronize to VC in the last page of the wizard.

2. Click the Simulation tab in the Ribbon, and click Play to start the solution. Or click Simulation in the Path View toolbar.

NOTE! Before the synchronization, make sure that all the paths in the current program are configured correctly.

How to prepare for a force control simulationWhen the Machining FC option is active in the current controller system, some special settings are required.

Before simulating a program that contains force control instructions, you should:

1. Press F5 to launch the virtual FlexPendant.

2. Click the ABB logo at the upper-right corner to open the ABB main menu.

3. Click Control Panel.

4. Click Configuration. From the Topics list which is located at the bottom of the virtual FlexPendant, select Motion. Double-click Robot. Select the currently used robot task, click Edit.

5. Double-click Use FC Master, select a FC Master for the robot.

6. Click OK to confirm, a warm start is required.

7. After the warm start, all the changes will take effect.


4 Workflow for Machining PowerPac4.8. How to Export Machining PowerPac Programs

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4.8. How to Export Machining PowerPac Programs

How to Export a Machining ProgramYou can choose to export the current work with Machining PowerPac as a RAPID program, or a RobotWare Machining Force Control program.

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To export a RAPID program:

1. Synchronize the current program to the virtual controller.

2. Select the task node in the Machining browser.

3. Click RAPID on the Machining ribbon-tab. A dialog box displays.

4. Specify the location where you want to save the program, and enter a name for the program.

5. Click OK, the RAPID program will be saved in the specified location.



4 Workflow for Machining PowerPac4.8. How to Export Machining PowerPac Programs

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To export a RWM program:

1. Select the task node in the Machining browser.

2. Click the RWM on the Machining ribbon-tab. A dialog box displays.

3. Select a process type from the FC Process Type drop-down list, specify a location where the export program will be stored and give a new name or use the default name for the export program.

4. Click OK, the program will be saved in the specified location.

Copy the exported file to the controller project folder "\HOME\MachiningFC\MFC Projects\", the file can be recognized by the RobotWare Machining FC graphical user interface. The RobotWare Machining FC is a controller software designed for high quality surface finishing and cast cleaning with Force Control option. All the exported paths from RobotStudio Machining PowerPac are taught paths. A learning process can be preformed based on the exported paths. See Application manual - Force Control for Machining.



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4.9 How to Create or Modify Templates

4.9.1. Overview

OverviewThree predefined templates are provided:

• Machining template, a template defining a set of specific move instructions, which can be customized in terms of machining process related properties.

• Approach/Departing template, a template defining how the robot moves close to a surface and withdraws from a surface. For approaching targets, their translation and orientation is referenced to the first target located in the surface. For the departing targets, their translation and orientation is referenced to the End target.

• Solution Configuration Template, a template defining all the parameters to be used to generate paths from a surface.

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Importing or Exporting TemplatesMachining PowerPac enables you to export and import templates. With this function you can backup the customized templates and share these templates with other Machining PowerPac users.

ExampleTo export Machining templates:

1. Right-click the Machining node in the Machining browser and click Export... on the shortcut menu to start the Export Machining Template dialog box.

2. Specify a location in Save in, enter a name for the new prt file in the File Name text box and click Save. All the templates under the Machining node will be saved as a prt file, which means an exported file may contain more than one machining template.

To import a prt file to Machining PowerPac:

1. Right-click the Machining node in the Machining PowerPac browser and click Import... on the shortcut menu to open the Import Machining Template dialog box.

2. In Look in browse to the location where the prt file is stored, select the desired file, and click Open.

3. All the Machining templates in the imported prt file will be displayed under the Machining node.

Template Exported file

Machining Templates .prt

Approach/Departing Templates .adt

Solution configuration Templates .pgs


4 Workflow for Machining PowerPac4.9.2. Machining Templates

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4.9.2. Machining Templates

OverviewA machining template is a collection of instruction settings and process parameters. Before creating paths in Machining PowerPac, a machining template should be selected and the corresponding instructions will be applied to the path.

Machining PowerPac provides the following templates by default:

NOTE!If the Force Control option is not selected in the current system, the FC_PressureProcess and FC_SpeedChangeProcess are not available and it is not possible to import a template with force control instructions.

Template Description

NormalProcess Always available.Includes the normal move instructions: MoveL, MoveJ and MoveC.

FC_PressureProcess Available when the Force Control option is selected in the current system.Includes force control instructions and supports the pressure process.

FC_SpeedChangeProcess Available when the Force Control option is selected in the current system.Includes force control instructions and supports the speed change process.




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Machining ModelingA machining process model is given as below:

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Machining Motion Part Description

Air Intermediate targets between path sections.A collection of robot targets where the robot will move fast and the motion type of the robot can be linear or joint.

Approach A collection of robot targets that leads the robot to move to the surface smoothly and safely.

Start The first target that locates on the surface, where some signals or events can be triggered.

Via A collection of robot targets that locate on the surface, and the motion type for Via targets is defined by the machining template.

End Normally, the end part is the first retract target where the robot can safely move to from the last target on the surface, and it’s also a synchronization point to trigger signals and events.Currently, the End target follows close behind the last Via target and locates in the position that is 3 mm in both the X and Z positive direction of the last Via target.

Departing A collection of robot targets that leads the robot to withdraw from the surface.




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Shortcut Menu from a Machining Template Node

Item Description

Create Copy Creates a copy template.

Rename Allows you to rename the selected template.

Remove Deletes the selected template.

Properties... Opens a dialog box with which you can view and edit the properties of the selected template.


4 Workflow for Machining PowerPac4.9.3. Approach/Departing Templates

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4.9.3. Approach/Departing Templates

OverviewEach Approach/Departing template has two parts to define the approaching section and the departing section of a machining path.

NOTE! Machining PowerPac defines special Approach/Departing templates with prefix FC as default for the learning process of RobotWare Machining FC. For example, if the FC_ObetuseAngle_135_deg is selected, the approach/departing targets expected relative position and orientation to Start target and End target is shown in the following figure. The Approach2, Approach3 and Start targets should along the x axis in an almost straight line, and the approaching angle to the surface is less than 20 degree. The End, Departing1 and Departing2 should be along the x axis in an almost straight line.

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Adding Approach/Departing Targets1. Right-click the Approach Target List or Departing Target List, click Add

Approach Target/Add Departing Target on the shortcut menu. A new target will be displayed in the browser with default position and orientation values.

2. Right-click the new target, click Properties... to start a dialog box.

3. Define the position and orientation in the dialog box.

4. Click Apply to apply the new values to the target.


4 Workflow for Machining PowerPac4.9.4. Solution Configuration Templates

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4.9.4. Solution Configuration Templates

OverviewDefines all parameters for generating a solution.

NOTE! SolutionConfiguration_RWMFC is provided by Machining PowerPac as default for RobotWare Machining FC.

Showing the Properties of a TemplateRight-click a template, and click Properties..., the dialog box with four tabs will open.

• Edit the parameters in this dialog box.

• Click Apply to make all changes take effect.

See How to Create Machining Solutions Based on Surface on page 34 for the detailed descriptions of the parameters.


4 Workflow for Machining PowerPac4.10. How to Create Calibrations

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4.10. How to Create Calibrations

OverviewIn most of cases, the part positions are different between the virtual cell and the real cell.

Machining PowerPac provides an easy way to adjust the positions by calibrating work object since all the robot targets are relative to the work object.

After creating all the paths offline, the calibration for paths should be done before applying the paths to work.

How to Create Calibration Data5 points calibration method is recommended.

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4 Workflow for Machining PowerPac4.10. How to Create Calibrations

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To create calibration in virtual world:

1. Click Calibration on the Machining ribbon-tab to open the dialog box.

2. Enter a name for the calibration in the text box.

3. Click in the 3D view to select 5 points not in a line or type values in the spin box under Point Position.

4. Select the check box of the work object to decide which work object in the list will be the reference work object.

5. Click Create, the new created calibration will be displayed in the Machining browser.

The Machining PowerPac will generate a RAPID procedure for this calibration.

How to Calibrate in Real WorldTo calibrate in real cell:

1. In real cell, select 5 points at almost the same positions as in the virtual world.

2. Call the generated RAPID procedure to update the work object. This will affect the value of the oframe, that is, the obejct frame of the work object.


5 Trouble Shooting5.1. About Path Generation Pattern

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What to do...Troubleshooting when using path generation patterns in the solution wizard:

When using... Trouble Description Try this ...

Cutting Planes Along Straight Line Cutting Planes Along Customized LineCircular Cutting Planes

The generated paths can not be seen from the Preview page of the Solution Wizard.

Probable cause: The cutting planes are parallel with the surface.Try this: Adjust the orientation of the cutting planes to ensure that the cutting planes intersect with the surface.Probable cause: The part is invalid.Try this: Close the wizard, use Check/Heal on the Machining ribbon-tab to heal the imported part.

ISO Parametric Lines

There is no curve generated.

Close the wizard, use Check/Heal on the Machining ribbon-tab to heal the imported part.If there is still no curve generated after running Heal, the surface may not be the supported format for this pattern.

Edges Edges can not be selected from the 3D view.

From the selection level toolbar of RobotStu-dio, make sure that Surface and Snap Edge are selected.If you still cannot select the edges, close the wizard. Use Check/Heal on the Machining ribbon-tab to heal the imported part.


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AApproach/Departing Template 95

EEdge 51

MMachining Template 92

FC_PressureProcess 92FC_SpeedChangeProcess 92NormalProcess 92

RRWM 19

SSchedule 9Solution 9Solution Configuration Template 96Spin Angle 10Surface 9

TTool Compensation 43Tool Working Range 9Travel Angle 10

WWork Angle 9

101

robotstudio 5.11 document id: 3hac030420-001...

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